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L-6 Engine

6A-1

ENGINE
33 THROUGH 86 SERIES
REFER TO PAGE 6K-1 FOR AIR INJECTION REACTOR SYSTEM ( K - 1 9 A N D K - 2 0 ) REFER TO PAGE. . 6L-1 FOR CARBURETION REFER TO PAGE. . . 6 M - 1 FOR V - 8 ENGINE REFER TO PAGE 6B-1 FOR T U N E - U P - L - 6 A N D V - 8 REFER TO PAGE 6C-1 FOR ENGINE C O O L I N G - L - 6 A N D V - 8 -

CONTENTS OF SECTION 6A—L-6 ENGINE

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Subject

Page 6A-16 6A-16 6A-16 6 A-17 6A-17 6A-18 6A-18 6A-18 6A-19 6A-20 6A-20 6A-20 6A-22 6A-22 6A-25 6A-26 6A-26 6A-26 6A-27 6A-28 6A-30 6A-30 6A-30 6A-31 6A-31 6A-31 6A-32 6A-32 6A-33 6A-33 6A-33 6A-34 6A-34 6A-35 6A-36

DESCRIPTION ENGINE ASSEMBLY REMOVAL INSTALLATION . MANIFOLD ASSEMBLY REMOVAL INSTALLATION ROCKER ARM COVER REMOVAL INSTALLATION ROCKER ARM ASSEMBLY REMOVAL INSTALLATION AND ADJUSTMENT . ROCKER ARM STUDS REMOVAL AND INSTALLATION . . . VALVE LIFTERS LOCATING NOISY LIFTERS REMOVAL INSTALLATION DISASSEMBLY CLEANING AND INSPECTION . . . . ASSEMBLY VALVE STEM OIL SEAL AND/OR VALVE SPRING REPLACEMENT (ON CAR) CYLINDER HEAD ASSEMBLY REMOVAL INSTALLATION DISASSEMBLY . CLEANING INSPECTION VALVE GUIDE BORES VALVE SEATS VALVES OIL PAN REMOVAL INSTALLATION OIL PUMP REMOVAL DISASSEMBLY CLEANING AND INSPECTION . . . . ASSEMBLY INSTALLATION REAR MAIN OIL SEAL REPLACEMENT TORSIONAL DAMPER

6A-2 6A-2 6A-2 6A-4 6A-4 6A-5 6A-5 6 A _5 6A-5 6 A _6 6 A _6 6A-6 6A_7 6A_7 6A_7 6A_8 6A_8
6A_9 6A_9

6A-10 6A-10 6A-10 6A-10 6A-10 6A-11 6A-12 6A-12 6A-13 6A-13 6A-13 6A-14 6A-14 6A-14 6A-14 6A-15 6A-15

REMOVAL INSTALLATION CRANKCASE FRONT COVER REMOVAL INSTALLATION OIL SEAL (FRONT COVER) REPLACEMENT CAMSHAFT MEASURING LOBE LIFT REMOVAL INSPECTION OIL NOZZLE REPLACEMENT . . . . CAMSHAFT GEAR REPLACEMENT . INSTALLATION CAMSHAFT BEARING REPLACEMENT TIMING GEAR REPLACEMENT. . . . MAIN BEARINGS CONNECTING ROD BEARINGS CONNECTING ROD AND PISTON REMOVAL DISASSEMBLY . PISTON PINS PISTON RINGS CRANKSHAFT REMOVAL CLEANING AND INSPECTION . . . . INSTALLATION CYLINDER BLOCK CLEANING AND INSPECTION . . . . OIL FILTER BY-PASS VALVE . . . . DISTRIBUTOR BEARING REPAIRS CYLINDER CONDITIONING CYLINDER BORING PISTON SELECTION FLYWHEEL REMOVAL INSTALLATION ENGINE MOUNTS ENGINE TORQUES SPECIFICATIONS FUEL PUMP - Refer to V-8 Engine . . TOOLS

6A-2

L-6 Engine

6. Disconnect wires at: • • • • • Starter Solenoid Delcotron Temperature Switch Oil Pressure Switch Coil

7. Disconnect: • • • • Accelerator linkage at manifold bellcrank. Exhaust pipe at manifold flange. Fuel line (from tank) at fuel pump. Vacuum line to power brake unit at manifold (if so equipped). • Power steering pump lines at pump end (if so equipped).

8. Raise vehicle and place on jack stands. 9. Remove propeller shaft.
Fig. 6A-1 DESCRIPTION L-6 Engine

NOTE: If plug for' propeller shaft opening in transmission is not available, drain transmission. 10. Disconnect:

The in-line L-6 250 cu. in. engine is standard in the 33 and 35 Series. (Fig. 6A-1) The L-6 engine cylinders are numbered from front to r e a r with the firing order 1-5-3-6-2-4. Crankshaft rotation as viewed from the rear is counterclockwise. The crankshaft has seven main bearings and the camshaft is supported by four bearings. Full pressure lubrication, through a full flow oil filter is furnished by a gear-type oil pump. The distributor, driven by a helical gear on the camshaft, drives the oil pump. The main oil gallery feeds oil, through drilled passages to the camshaft and crankshaft to lubricate the bearings. The main oil gallery, also feeds the valve lifters which, through hollow push rods, feed the individually mounted rocker arms. (Fig. 6A-2)

• Shift linkage at transmission. • Speedometer cable at transmission. 11. On manual transmission equipped vehicles, disconnect clutch linkage at cross shaft, then remove cross shaft engine bracket. 12. Remove transmission assembly. 13. Remove front mount through bolts. 14. Attach BT-6606 and raise engine to take weight off front mounts, then remove rear mount bolts. (Fig. 6A-3) 15. Remove engine assembly from vehicle as a unit. 16. Mount engine in stand.

ENGINE ASSEMBLY
Installation Removal

1. Drain cooling system and engine oil. 2. Remove air cleaner and disconnect battery cables at battery. 3. Remove hood. 4. Remove radiator shroud. 5. Remove fan blade and pulley.

1. Attach BT-6606 to engine and remove engine from engine stand. 2. Tilt and lower engine assembly into the chassis, guiding engine to align front mounts with frame supports. 3. Install front mount through bolts and torque to specifications. 4. Raise engine enough to install rear cross-

L-6 Engine

6A-3

OIL PRESSURE SENDING UNIT

Fig. 6A-2

Engine Lubrication

If necessary to replace either intake or exhaust manifolds. Remove air cleaner. Connect: • Speedometer cable. Install transmission assembly. Connect battery cables. 9. • Accelerator linkage at manifold bellcrank. Install propeller shaft. Perform necessary adjustments and install air cleaner. engine oil and transmission oil. 6. Transfer all necessary parts. Install bolts and clamps while holding manifold in place with hand. Check for cracks in manifold castings. 5. Install pulley. Disconnect exhaust pipe at manifold flange and discard packing. Connect wires at: • • • • • Coil Oil pressure switch Temperature switch Delcotron Starter solenoid 5. 8. 3. Center bolt and end bolt torque 11. Disconnect crankcase ventilation hose at rocker arm cover. Clean gasket surfaces on cylinder head and manifolds. separate them by removing one bolt and two nuts at center of assembly. • Fuel line at fuel pump. 4. 10. Fill with coolant. then start engine and check for leaks. 14. it will be necessary to replace the manifold. then remove manifold assembly and discard gaskets. fan blade and fan belt. Check operation of heat r i s e r valve. 2. 12. MANIFOLD ASSEMBLY Removal 1. 6. Disconnect carburetor. 13. . Connect exhaust pipe to manifold using a new packing. Installation 1. Install radiator and shroud. Torque bolts to specifications. Tighten finger tight and torque to specifications after assembly to cylinder head. Connect: • Power steering pump lines (if disconnected). fuel and vacuum lines at 4. lower engine and torque bolts to specifications. Remove jack stands and lower vehicle. install rear mount. if unable to free up. 5. 7. Disconnect both throttle rods at bellcrank and remove throttle return spring. • Vacuum line to power brake unit (if disconnected). 9. Install and adjust hood. 3.6A-4 L-6 Engine 15. 16. • Exhaust pipe at manifold flange. 2. Fig. Remove manifold attaching bolts and clamps. • Shift linkage at transmission. then install crossmember. Reassemble manifolds using a new gasket. 6A-3 Lifting Engine member. 7. NOTE: differ. Position new gasket over manifold end studs on head and carefully install the manifold in position making sure the gaskets are in place. 8.

6A-4 Valve Adjustment Installation and Adjustment NOTE: Whenever new rocker arms and/or rocker a r m balls are being installed. 2. 1. one cylinder at a time. 3. Disconnect temperature wire from arm cover clips. rocker arms and push rods. Tighten rocker arm nuts until all lash is eliminated. Remove rocker arm cover. Disconnect crankcase ventilation hose(s) at rocker arm cover. Crank engine until distributor rotor points to number one cylinder position and breaker points are open. in the same manner. turn adjusting nut in one full additional turn (to center lifter plunger). install rocker arm cover and bolts to specifications. This can be determined by checking push rod side play while turning adjusting nut. 7 Connect fuel and vacuum lines at carburetor. Install rocker arms. Gaskets adhering to cylinder head and rocker arm cover may be sheared by bumping end of rocker arm cover rearward with palm of hand or a rubber mallet. d. g Connect throttle rods at bellcrank and install throttle return spring. 4. . ROCKER ARM COVER Removal 1. check for leaks and adjust carburetor idle speed and mixture. Be sure push rods seat in lifter socket. Remove air cleaner. ROCKER A R M ASSEMBLY Removal 1. coat bearing surfaces of rocker arms and rocker arm balls with Molykote or its equivalent. Connect crankcase ventilation hoses. 6A-4) When play has been removed. Both valves on number one cylinder may now be adjusted. Install push rods. (Fig. Mark distributor housing. 3. rocker Fig. c. 4. at each cylinder position (plug wire). Remove rocker arm nuts. Adjust the remaining valves.L-6 Engine 6A-5 A Connect crankcase ventilation hose at rocker arm cover. NOTE: Place rocker arms. Back out adjusting nut until lash is felt at the push rod. NOTE: Do not pry rocker arm cover loose. Adjust valves when lifter is on base circle of camshaft lobe as follows: a. 3. then turn in adjusting nut until all lash is removed. wire at rocker arm 2. then disconnect plug wires at spark plugs and coil and remove distributor cap and plug wire assembly (if not previously done). Remove rocker arm cover as outlined. then using gasket. rocker arm balls and push rods in a rack so they may be reinstalled in the same location. Install air cleaner. Installation 1. 2. 2. Clean rocker a new torque gasket surfaces on cylinder head and arm cover with degreaser. rocker arm balls. b. 9 Install air cleaner. start engine. rocker arm balls and rocker arm nuts. Connect temperature cover clips. with chalk.

Locate a noisy valve lifter by using a piece of garden hose approximately four feet in length. and servicing of the lifters requires only that care and cleanliness be exercised in the handling of parts. 6A-6. The lifters are extremely simple in design.S. 6 A . Install new stud as shown in Fig. Install distributor cap and spark plug wire assembly. NOTE: Oversize studs have the size marked on the bottom.7 Removing Stripped Rocker Arm Stud Fig. 6A-6. 6A-7 for rethreading and Fig. Adjust carburetor ROCKER ARM STUDS 1. Place one end of the hose near the end of each . 5. tool should bottom on head. 6 A . 6 A . If rocker arm stud is loose or pulled out of head refer to Fig. If rocker arm stud is stripped refer to Fig. tool should bottom on head. idle speed and mixture. 2. Install new O.8 Removing Rocker Arm Stud VALVE LIFTERS Hydraulic valve lifters very seldom require attention. 4. Fig.5 Reaming Rocker A r m Stud Hole 4. 6 A . Locating Noisy Lifters Fig. stud as shown in Fig. Install rocker arm cover as outlined. readjustments are not necessary.6 I n s t a l l i n g Rocker Arm Stud 3.6A-6 L-6 Engine Fig. 6A-8 for pulling the stud. 6. 6A-5 and ream stud hole to next largest size.

be a definite indication of insufficient oil supply. it niore than likely exists in all the units. Excessive varnish or carbon deposit causing abnormal stickiness. Improper adjustment. carbon. Hard Rapping Noise--Usually caused by the plunger becoming tight in the bore of the lifter body to such an extent that the return spring can no longer push the plunger back up to working position. b. Install distributor. 3. Install push rod covers. Both lifters are easily identified by the outside configuration of the lifter body. adjust valve mechanism as 5. In this manner. or improper adjustment. is shown to exist in one unit. varnish. Remove the plunger. positioning rotor to number one cylinder position. 2. thus it would only be a matter of time before all lifters caused trouble. b. Mark distributor housing. Remove push rod covers (discard gaskets).. coat foot of valve lifters with Molykote or its equivalent. the sound is localized making it easy to determine which lifter is at fault. In most cases where noise exists in one or more lifters all lifter units should be removed. Remove valve lifters. For purposes of identification we refer to them as lifter " A " and lifter " B " .This will. Two types of hydraulic lifters are used. then disconnect distributor primary lead at coil and remove distributor. 2. reassembled. disassembled. In r a r e cases. cleaned in a solvent. Improper adjustment. Install valve lifters. If dirt. in almost all cases. etc. and using the blade of a small screw driver. If the lifter is not functioning properly. Leaky check valve seat. c. and torque bolts to specifications. (Fig. then connect primary lead at coil. then disconnect plug wires at spark plugs and coil and r e move distributor cap and plug wire assembly. The complete lifter assemblies are interchangeable but parts from one lifter are not interchangeable with another. b. VALVE LIFTERS (HYDRAULIC) a. Both types of lifters operate on the same principle and are serviced basically in the same manner. Crank engine until distributor rotor points to number one position. Probable causes are: a. a distinct shock will be felt when the valve returns to its seat. usually caused by an abrasive piece of dirt or metal wedging between plunger and lifter body. and reinstalled in the engine. Another method is to place a finger on the face of the valve spring retainer. 2.Probable causes are: a. remove the push rod seat retainer. NOTE: Whenever new valve lifters are being installed. Installation 1. Hold the plunger down with a push rod. 4. Adjust ignition timing and carburetor idle speed and mixture. 2. Remove valve mechanism as outlined.. with chalk. 3. Intermittent Clicking--Probable causes are: cylinder position (plug wire). The general types of valve lifter noise are as follows: 1. (Fig. 6A-10) 3. General Noise Throughout the Valve Train . Moderate Rapping Noise . Install a n d outlined. 5. ball check valve assembly and the plunger spring. c. 3. Galling or "pickup" between plunger and bore of lifter body. A microscopic piece of dirt momentarily caught between ball seat and check valve ball. 4. Remove the push rod seat and metering valve (lifter "A") or the push rod seat and inertia valve assembly (lifter " B " ) .m L-6 Engine 6A-7 •ntake and exhaust valve with the other end of the hose to the ear. NOTE: Place valve lifters in a rack so they may be reinstalled in the same location. 6A-9) Disassembly 1. 4. the ball itself may be outof-round or have a flat spot. Removal 1. at each . Excessively high leakdown rate. using new gaskets.

6A-10 Removing Ball Check Valve NOTE: Inertia valve and retainer (lifter "B") (Fig. (Fig. Place the check ball on small hole in bottom of the plunger. inspect the cylinder block lifter bore. 6A-11) 3.6A-8 L-6 Engine LIFTER " A " LIFTER "B' Fig. 6A-10) Thoroughly clean all parts in cleaning solvent. To check the valve. and inspect them carefully. 6A-9) should not be removed from the push rod seat. 4. 6. . if the push rod seat is scuffed or worn inspect the push rod. At this point oil holes in the lifter body and plunger assembly will be aligned. the entire lifter assembly should be replaced: If the lifter body wall is scuffed or worn. (Fig. Remove the ball check valve and spring by prying the ball retainer loose from the plunger with the blade of a small screw driver. shake the push rod seat and inertia valve assembly and the valve should move. Insert check ball spring on seat in ball retainer and place retainer over ball so spring r e s t s on the ball. Place the plunger spring over the ball retainer and slide the lifter body over the spring and plunger. Insert a 1/16" drift pin through both oil holes to hold the plunger down against the lifter spring tension. (Fig. (Fig. 6A-9) the drifter pin must not extend inside the plunger. If any parts are damaged or worn. Assembly 1. Carefully press the retainer into position in plunger with the blade of a small screw driver. 5. 2. Cleaning and Inspection 1 Lifter Body 2 Push Rod Seat 3 Metering Valve (Lifter A) Inertia Valve (Lifter B) 4 Check Ball Fig. 6A-9 5 6 7 8 9 Check Ball Retainer Push Rod Seat Retainer Plunger Check Ball Spring Plunger Spring Valve Lifter Assemblies 4. 6A-12) NOTE: Do not attempt to force or pump the plunger. being careful to line up the oil feed holes in the lifter body and plunger. Fill the assembly with SAE 10 oil. refill assembly with SAE 10 oil. if the bottom of the lifter is scuffed or worn inspect the camshaft lobe. Remove the 1/8" drift pin. 6A-12) NOTE: On lifter " B " (Fig. then insert the end of a 1/8" drift pin into the plunger and press down solid.

6A-13 Removing Valve Spring V A L V E STEM O I L SEAL A N D / O R VALVE SPRING Replacement (On Car) 1. 6. NOTE: A tool to apply air to the cylinders to hold the valve is available. 6A-12 Assembling Hydraulic Lifters 7. valve shield and valve spring and damper. coat the bottom of the lifter with Molykote or its equivalent. Compress the spring with Tool BT-6413 and install oil seal in the lower groove of the stem. 7. set the valve spring and damper. 6A-11 Installing Ball Check Valve 3. press down on the push rod seat and remove the 1/16" drift pin from the oil holes. valve cap. Using the tool the valves can be removed with the cylinder head installed. Remove spark plug. . Install the push rod seat retainer. Remove rocker arm cover as outlined. 6A-13) 5. (Fig. To replace. making sure the seal is flat and not twisted. NOTE: Before installing any new lifters. The lifter is now completely assembled. Install the metering valve and push rod seat (lifter "A") or the push rod seat and inertia valve assembly (lifter " B " ) . NOTE: A light coat of oil on the seal will help prevent twisting. rocker arm and push rod on the cylinder(s) to be serviced. (Fig. making sure the locks seat properly in the upper groove of the valve stem. NOTE: Grease may be used to hold the locks in place while releasing the compressor tool. The close coiled end of the spring is installed against the cylinder head. 2. Using Tool BT-6413 to compress the valve spring. 4.L-6 Engine 6A-9 Fig. valve shield and valve cap in place. 6A-9) 8. Apply compressed air to the spark plug hole to hold the valves in place. Install the valve locks and release the compressor tool. remove the valve locks. filled with oil and ready for installation. Remove the valve stem oil seal. Fig. BT-72-1-B. Fig.

cylinder head and gasket. 2. 9. radiator hose and engine Fig.) Do not use gasket sealer on composition steel asbestos gasket. Install manifold assembly as outlined. and torque to specifications. Start engine and allow warm up. 11. 5. Disconnect upper radiator hose at water outlet housing and battery ground strap at cylinder head. Install and adjust valve mechanism as outlined. Thoroughly clean the valve guides. 4. Tighten head bolts a little at a time until the specified torque is reached. (Fig. CYLINDER HEAD ASSEMBLY 7. spring shields. Clean all carbon from combustion chambers and valve ports. Clean all carbon and sludge from push rods. Carefully guide cylinder head into place over dowel pins and gasket. Remove valves from cylinder head and place them in a rack in their proper sequence so they can be assembled in their original positions. 3. Installation 1. Coat threads of cylinder head bolts with sealing compound and install finger tight. springs and spring damper. 8. Connect temperature sending unit wires and install fuel and vacuum lines in clip at water outlet. remove valve rocker arm nuts. 2. Install and adjust valve mechanism as outlined. Fill cooling system. 1. 10. 7. using a new gasket. Remove fuel and vacuum line from retaining clip at water outlet. 3. remove oil seals and valve spring shims. then disconnect wires from temperature sending units. Using a valve spring compressing tool. then. 5. 6A-15) 2. With cylinder head removed.1 4 Compressing V a l v e Springs 8. Remove manifold assembly as outlined. 2. then retorque cylinder head and readjust valves. Place the gasket in position over the dowel pins with the bead up. 9. Install spark plug. Place cylinder head on two blocks of wood to prevent damage. NOTE: Do not install rocker arm cover. Connect upper ground strap. 6. 3. (Dirt will affect . Install coil.6A-10 L-6 Engine bolt torque. 6 A . rocker arms and push rod guides. NOTE: The gasket surfaces on both the head and the block must be clean of any foreign matter and free of nicks or heavy scratches. compress the valve springs (Fig. 6A-16) 3. 6. Cleaning 1. Cylinder bolt threads in the block and threads on the cylinder head bolt must be cleaned. (Fig. Drain cooling system (block). Release the compressor tool and remove spring caps. Remove valve mechanism as outlined. ball and rocker arms (if not previously done). Disassembly ' Removal 1. 4. 6A-14) and remove valve keys. Remove cylinder head bolts. Remove coil.

2. 6A-17 Fig. if not within 10 lbs. Inspection Valves with oversize stems are available. NOTE: Excessive valve stem to bore clearance will cause excessive oil consumption and may cause valve breakage. Clean valve stems and heads on a buffing wheel. using light pressure to obtain a clearance reading. 3. move the stem of the valve from side to side.L-6 Engine 6A-11 Fig. cracked faces or damaged stems. combustion chambers or external cracks to the water chamber. 6A-18) See Specification chart. If clearance exceeds specifications. of the specified load (without damper) the spring should be replaced. 6A-17) as follows: Clamp a dial indicator on one side of the cylinder head rocker arm cover gasket rail. Clean carbon deposits from head gasket mating surface. With the valve head dropped about 1/16" off the valve seat. 5. The indicator stem must contact the side of the valve stem just above the valve guide. (Fig. Inspect the cylinder head for cracks in the exhaust ports. (Fig. the springs can be checked. 6A-15 Cleaning Combustion Chamber Measuring Valve Stem Clearance the head) will cause a direct movement of the indicator stem. Inspect rocker arm studs for wear or damage. Inspect the valves for burned heads. Insufficient clearance will result in noisy and sticky functioning of the valve and disturb engine smoothness. VALVE GUIDE BORES Fig. it will be necessary to ream valve guides for oversize valves as outlined. 6A-18 Checking Valve Spring Tension . Clean and inspect valve springs. 6A-16 Cleaning Valve Guide 4. 6A-19) 1. Measure valve stem clearance (Fig. If a spring tension tool is available. locating the indicator so that movement of the valve stem from side to side (crosswise to Fig. To ream the valve guide bores for oversize valves. use Tool Set J-5830.

Measure valve concentricity. Good contact between each valve and its seat in the head is imperative to insure that the heat in the valve head will be properly carried away. it is essential that valve guide bores be free from carbon or dirt to insure proper centering of pilot in the guide. 6A-21) Fig. When a valve head which is warped excessively is refaced. 6A-20. Regardless of what type of equipment is used. place finishing stone. 6A-20 Relation of Valve and Seat Angles NOTE: This operation is done by grinding the port side with a 30° stone to lower seat and a 60° stone to raise seat. cut to specifications. The recommendations of the manufacturer of the equipment being used should be carefully followed to attain proper results. 6. 4. Place roughing stone or forming stone over pilot and just clean up the valve seat. Fig. Knife edges lead to breakage. Several different types of equipment are available for reseating valve seats. Refer to specifications and Fig. 5. burning or . however. Remove roughing stone or forming stone from pilot. VALVES Valves that are pitted can be refaced to the proper angle. 3.6A-12 L-6 Engine INTERFERENCE Fig. 6A-19 V A L V E SEATS Reaming Valve Guide Bores Reconditioning the valve seats is very important. a knife edge will be ground on part or all of the valve head due to the amount of metal that must be removed to completely reface. over pilot and cut just enough metal from the seat to provide a smooth finish. on a valve refacing mechanism. 6A-21 Measuring Valve Seat Concentricity NOTE: Valve seats should be concentric to within . (Fig. insuring correct relation between the head and stem. 2. Use a stone cut to specifications. 002" total indicator reading. because the seating of the valves must be perfect for the engine to deliver the power and performance built into it. Remove expanding pilot and clean cylinder head carefully to remove all chips and grindings from above operations. Install expanding pilot in the valve guide bore. Another important factor is the cooling of the valve heads. Valve stems which show excessive wear or valves that are warped excessively should be replaced. Narrow the valve seats to the specified width. 1.

Fig. To remove the engine oil pan. install a valve spring seat shim approximately 1/16" thick. Several different types of equipment are available for refacing valves. Set check at angle specified for valve. Be sure the seal is flat and not twisted. 5. 8. (Fig. (Fig. d. Assembly Fig. valve damper. 6. 6A-24) Measure from the top of the shim or the spring seat to the top of the valve spring shield. The recommendations of the manufacturer of the equipment being used should be carefully followed to attain proper results. 7. Refer to specifications and Fig. Operate the vacuum and make sure no air leaks past the seal. If this makes the valve head thin (1/32" min. Compress the spring. making sure the locks seat properly in the upper groove of the valve stem.) the valve must be replaced as the valve will overheat and burn. dress the valve refacing machine grinding wheel to make sure it is smooth and true. A cutaway scale will help. Check each valve stem oil seal by placing a vacuum cup or similar device over the end of the valve stem and against the cap. OIL PAN 1. b. If all pencil marks have not been removed at the point of contact with the valve seat. Do not grind end of stem excessively. e If t n e e < ^S e °f t n e v a l v e head is less than W32" thick after grinding. 2. OIL PUMP The oil pump consists of two gears and a pressure regulator valve enclosed in a two-piece housing. NOTE: Grease may be used to hold the locks in place while releasing the compressor tool. 6A-22 Valve Spring Installation c.L-6 Engine 6A-13 ignition due to heat localizing on this knife P. 3. Set the valve spring shim. 6A-26) . 6A-20. it will be necessary to repeat the refacing operation and again recheck for proper seating. Removal and Installation. Continue grinding until the valve face is true and smooth all around the valve. Remove valve from chuck and place stem in " V " block. it is necessary to remove the engine from the car. 6A-25) If this is found to exceed the specified height. (Fig. Assemble the valve spring and related parts as follows: a. A vacuum cup can be made from a small syringe and a high voltage shield. Refer to ENGINE. Move valve back and forth across the wheel and regulate the feed screw to provide light valve contact. Grind and check the remaining valves in the same manner. Clamp the valve stem in the chuck of the machine. Turn the feed screw until the valve head just contacts wheel. (Fig. NOTE: Only the extreme end of the valve stem is hardened to resist wear. After cleaning valve face and cylinder head valve seat of grinding particles. Check the installed height of the valve springs using a narrow thin scale. Install oil seal in lower groove of stem. Feed valve squarely against grinding wheel to grind any pit from rocker arm end of stem. At no time should the spring be shimmed to give an installed height under the minimum specified. 9. 6A-25A illustrates gasket and seal installation. Insert a valve in the proper port. Install the valve locks and release the compressor tool. 3. Install the remaining valves. 2. place the valve in cylinder head and give the valve 1/2 turn in each direction while exerting firm pressure on head of valve. valve shield and valve cap in place. 4. The oil pump is driven by the distributor shaft which is driven by the helical gear on the camshaft. Remove valve and check face carefully. 4. I If necessary. make pencil marks about 1/4" apart across the valve face. replace the valve. valve spring. Start the grinder and move the valve head in line with the grinder wheel. 6A-22) The close coiled end of the spring is installed against the cylinder head.

6A-16

L-6 Engine

Fig. 6A-30

Removing Torsional Damper

Fig. 6A-29

Removing O i l Seal (Upper Half)

4. To remove the upper half of the seal, use a small hammer to tap a brass pin punch on one end of seal until it protrudes far enough to be removed with pliers. (Fig. 6A-29) NOTE: Always clean crankshaft surface removing all foreign deposits before installing a new seal. Also clean seal grooves. 5. Lubricate the lip and OD of a new seal with engine oil. Keep oil off the parting line surface. Gradually push with a hammer handle, while turning crankshaft, until seal is rolled into place. (Similar to installing a main bearing. ) Be careful that seal bead on OD is not cut. Compress seal towards crankshaft as much as possible. 6. Install the rear main bearing cap (with new seal) and torque to specifications. Be sure cross seal tabs are in place and properly seated.
TORSIONAL DAMPER Removal

Fig. 6A-31

Installing Torsional Damper

3. Install tools as shown in Fig. 6A-30 and remove damper. Remove tools.
Installation

1. Coat front cover oil seal contact area of damper with engine oil. 2. Position damper on crankshaft and drive into position, using J-5154, until it bottoms against crankshaft gear. (Fig. 6A-31) 3. Install belts and adjust. 4. If so equipped, install accessory drive pulley and belt. 5. Install radiator, fill cooling system and check for leaks.
CRANKCASE FRONT COVER Removal

1. Remove oil pan as outlined. 2. Remove outlined. crankshaft torsional damper as

1. Remove radiator core. 2. Remove fan belt and (if so equipped) accessory drive pulley and belt.

L-6 Engine

6A-17

Fig. 6A-33

Installing Oil Seal (Cover Removed)

NOTE:
Fig. 6A-32 Installing Front Cover

Support cover at sealing area.

3. Remove crankcase front cover attaching bolts, cover and gasket.
Installation

Without Cover Removal

1. Clean gasket surfaces on block and crankcase front cover. 2. Install centering Tool J-21742 in crankcase front cover seal. (Fig. 6A-32) 3. Coat the gasket with gasket sealer and place in position on cover, then install crankcase front cover to block and torque bolts to specifications. 4. Remove centering tool. NOTE: It is important that centering tool be used to align crankcase front cover so that crankshaft hub or torsional damper installation will not damage seal and to position seal evenly around the balancer or hub surface. 5. I n s t a l l crankshaft torsional damper as outlined. 6. Install oil pan with new gaskets and seals as outlined.
OIL SEAL (FRONT COVER) Replacement ( W i t h Cover Removal)

1. With crankshaft torsional damper removed, install tools as shown in Fig. 6A-34 and remove seal. 2. Install new seal so that open end of seal is toward the inside of cover and drive it into position with ToolJ-8340. (Fig. 6A-35)

1. With cover removed, pry old seal out of cover from the front with screw driver being careful not to distort cover. 2. Install new seal so that open end of the seal is toward the inside of cover and drive it into position with T o o l J - 995. (Fig. 6 A-33)

Fig. 6A-34

Removing O i l Seal (Cover Installed)

6A-18

L-6 Engine

cam lobe. At this point, the push rod will be in its lowest position. 4. Set dial indicator on zero, then rotate the crankshaft slowly, or attach an auxiliary starter switch and "bump" the engine over, until the push rod is in the fully raised position. NOTE: The primary distributor lead must be disconnected from the negative post on the coil and the ignition switch must be in the ON position. Failure to do this will result in a damaged grounding circuit in the ignition switch. 5. Compare the total lift recorded from the dial indicator with specifications. 6. Continue to rotate the crankshaft until the indicator reads zero. This will be a check on the accuracy of the original indicator reading.
Fig. 6A-35 CAMSHAFT Installing O i l Seal (Cover Installed)

7. If camshaft readings for all lobes are within specifications, r e m o v e dial i n d i c a t o r assembly. 8. I n s t a l l outlined. and a d j u s t valve mechanism as

Measuring Lobe l i f t

NOTE: Procedure is similar to checking valve timing. If improper tion is indicated, measure the lift rod in consecutive order and record

that used for valve operaof each push the readings.

Removal

1. Remove valve lifters. 1. Remove valve mechanism as outlined. 2. Remove crankcase front cover. 2. Position indicator with ball socket adapter on push rod. (Fig. 6A-36) 3. Rotate the crankshaft slowly in the direction of rotation until the lifter is on the heel of the 3. Remove grille. 4. Remove fuel pump. 5. Align timing gear marks then remove the two camshaft thrust plate bolts by working through holes in the crankshaft gear. (Fig. 6A-37) 6. Remove the camshaft and gear assembly by pulling it out through the front of the block. NOTE: Support camshaft carefully when removing so as n o t to damage camshaft bearings.

Inspection

The camshaft bearing journals should be measured with a micrometer for an out-of-round condition. If the journals exceed .001" out-of-round, the camshaft should be replaced. The camshaft should also be checked for alignment. The best method is by use of " V " blocks and a dial indicator (Fig. 6A-38). The dial indicator will indicate the exact amount the camshaft is

Fig. 6A-36

Measuring Camshaft Lobe Lift

Drive new nozzle in place (oil hole in vertical position) using a suitable light plastic or rubber hammer. . 6A-4J Removing Camshaft Gear Inspect the camshaft gear and thrust plate for wear or damage.002" dial indicator reading. 6A-39 Checking Camshaft End Play REPLACEMENT 1. out of true. (Fig.001" to . (Fig. the camshaft should be replaced.005". 6A-37 Timing Gear Marks Fig.L-6 Engine 6A- Fig. 6A-40) 2. 6A-39) OIL N O Z Z L E Fig. 6A-38 Checking Camshaft Al ignment Fig. If it is out more than . This should be . 6A-40 O i l Nozzle Replacement Fig. Remove nozzle with pliers. Measure the camshaft end play.

Check the backlash between the timing gear teeth with a dial indicator. Install camshaft thrust plate to block bolts and torque to specifications. 6A-44 Checking Camshaft Gear Runout 6. 7. To assemble cam shaft gear and thrust plate. (Fig. Install crankcase front cover. Install valve lifters.004" and the crankshaft gear runout should not exceed . 5. use an arbor press and Tool as shown in Fig. 3.004" nor more than .6A-20 L-6 Engine Fig. Install the camshaft and gear assembly in the engine block.003". If gear runout is excessive.006". (Fig. 9. 6A-45) The backlash should not be less than . 6A-43). 6A-44) The camshaft gear runout should not exceed . 2. Turn crankshaft and camshaft so that the valve timing marks on the gear teeth will line up (Fig. gear or thrust plate should be replaced. 6A-42. 3. Fig. 6A-43 Timing Gear Marks 1. 8. Check camshaft and crankshaft gear runout with a dial indicator. 6A-41 for gear removal. Installation Fig. If the inspection indicates that the shaft. 6A-42 Installing Camshaft Gear C A M S H A F T GEAR REPLACEMENT 1. 2. Install fuel pump. NOTE: Thrust plate must be positioned so that woodruff key and shaft does not damage it when the shaft is pressed out of gear. being careful not to damage camshaft bearings or camshaft. the gear will have to' be removed and any burrs cleaned from the shaft or the gear will have to be replaced. oil pan and oil pump . Place the gear on the shaft until clearance shown in Fig. 6A-42 is obtained. the gear should be removed from the shaft. 4. Install grille. CAMSHAFT BEARINGS Removal Camshaft bearings can be replaced while the engine is removed for overhaul by removing the following parts: front cover. Refer to Fig. Push camshaft into position.

2 & 3 Camshaft Bearing . Fig. 2. With pilot installed as shown in Fig. NOTE: Slide slip ring forward on jaws of tool so that tool will enter behind the bearing. 3 and 2. 6A-46. intact. 2 and 3 using tools as shown in Fig. 4. after positioning the tool behind the bearing pull the ring rearward so jaws of tool will expand behind the bearing. With camshaft removed. 1. 6A-46 Removing No. 1. pull No. Using tools shown in Fig. Installation Fig. drive out cam bearing No. 6A-47. 6A-45 Checking Timing Gear Backlash 1. NOTE: After driving out No. 2 and 3. 1. Leave cylinder head and pistons 1. 6A-46. install bearings No.L-6 Engine 6A-21 and camshaft. install pilot to drive out No. 4 bearing.

For this reason. 2. If clearances are found to be excessive. 4. will be required.030" undersize.010". 6-49. . To install crankshaft gear use Tools shown in Fig. 3 and 2 in until the white marks on tool are flush with the pilot. it is then ground .002". . Fig. Bearings are available in standard size and . Fig. TIMING GEARS Replacement With camshaft removed. 6A-48 Removing Crankshaft Gear M A I N BEARINGS Main bearings are of the precision insert type and do not utilize shims for adjustment. 6-48. 6A-49 Installing Crankshaft Gear When a production crankshaft cannot be precision fitted by this method. a new bearing.001". 4 Camshaft Bearing NOTE: Make sure oil holes are aligned.6A-22 L-6 En gme Fig. 6A-47 Removing No. To install bearing No.0005" from using a full standard bearing. . Drive bearings No. . crankshaft gear may be removed using Tools shown in Fig. both upper and lower halves. Selective fitting of both rod and main bearing inserts is necessary in production in order to obtain close tolerances. you may find one-half of a standard insert with onehalf of a .009". 009" .020" and . remove pilot and thread BT-6609-3 onto Handle BT-6609-5 and drive bearing into block until white line on Tool BT-6609-3 is flush with face of block.001" undersize insert which will decrease the clearance . 1.

certain precautions should be observed. 5. 1. 6A-50) NOTE: Do not rotate the crankshaft while the gauging plastic is between the bearing and journal. Without removing the gauging plastic. it can be assumed that the upper half is also satisfactory.010" undersize bearing may be used for precision fitting in the same manner as previously described.L-6 Engine 6A-23 Fig. the surface of the crankshaft journal and bearing should be wiped clean of oil. If upon inspection. A Figure "9" will be stamped on the block at the left front oil pan rail. the crankshaft will rest on the upper bearings and the total clearance can be measured between the lower bearing and journal. 6A-50 Gauging Plastic on Journal Fig. Place a piece of gauging plastic the full width of the bearing (parallel to the crankshaft) on the journal. The total clearance can then be measured between the lower bearing and journal. Remove bearing cap. Laminated shims for each cap are available for service. 6A-51 Measuring Gauging Plastic undersize on main journals only. both upper and lower halves should be replaced. shimming may be necessary. If the lower half shows evidence of wear or damage. 2.009" undersize bearing and . The flattened gauging plastic will be found adhering to either the bearing shell or journal. (Fig. 2. remove bearing cap and wipe oil from journal and bearing cap. preparatory to checking fit of bearings. Any engine fitted with a . for any reason. ". 3. If the engine is out of the vehicle and . Install the bearing cap and evenly torque the retaining bolts to specifications. main bearing caps are replaced. all bearing cap bolts should be at their specified torque. NOTE: If. (or its equivalent) a wax-like plastic material which will compress evenly between the bearing and journal surfaces without damaging either surface. In addition. NOTE: To assure the proper seating of the crankshaft. the lower half of the bearing shows a greater wear and the most distress f r o m fatigue. Never replace one-half without replacing the other half.009" undersize crankshaft will be identified by the following markings. Shim requirement will be determined by bearing clearance. 1. If the engine is to remain in the vehicle. the lower half is suitable for use. With the oil pan and oil pump removed and starting with the rear main bearings. Inspection upside down. 4. the crankshaft should be supported both front and rear (damper and flywheel) to remove the clearance from the upper bearing. Checking Clearance To obtain the most accurate results with Plastigauge. measure its compressed width (at the widest point) In general. A .009" will be stamped on the crankshaft counterweight forward of the center main journal. On the edge of gauging plastic envelope there is a graduated scale which is correlated in thousandths of an inch.

» 6.002" undersize bearing may produce the proper clearance. there is a difference in clearance indicating taper. If the bearing clearance is with specifications. Use a small drift punch and hammer to start the upper bearing half rotating out of block. (Fig. interference between the bearing and journal will result in rapid bearing failure. if a bearing is being fitted to an out. low spot or other irregularity of the bearing or journal. (Fig. Measure crankshaft end play (see specifications) by forcing the crankshaft to the extreme front position. Without Crankshaft Removal 1. rotate the crankshaft to see that there is no excessive drag. The rear main journal has no oil hole. Replacement NOTE: Main bearings may be replaced with or without removing the crankshaft. 6A-52 Measuring Crankshaft End Play Fig. replace the insert. With oil pan. NOTE: If a new bearing cap is being installed and clearance is less than . inspect for burrs or nicks. 6A-51) NOTE: Normally. oil pump and spark plugs removed. Be sure to measure the journal with a micrometer if the flattened gauging plastic indicates more than . the bearing insert is satisfactory. 7. then install shims as required. If the flattened gauging plastic tapers toward the middle or ends. If the bearing is fitted to the minimum diameter and the journal is out-of-round . 2. 2. Remove and inspect the crankshaft. be sure to fit to the maximum diameter of the journal.001" max.001". 4. 3. A . If not. it will be necessary to regrind the crankshaft journal for use with the next undersize bearing. If the clearance is not within specifications. Install the crankshaft. Replace the r e a r main bearing upper half as follows: a.6A-24 L-6 Engine Fig. Coat bearing surfaces of new.001" difference.001". 6A-52) 10. correct size. 8. . After all bearings have been checked. Proceed to the next bearing. main bearing journals wear evenly and are not out-of-round.ofround journal (. If none are found. Measure at the front end of the r e a r main bearing with a feeler gauge. W i t h Crankshaft Removal 1. remove cap on main bearing requiring replacement and remove bearing from cap. main bearings with oil and install in the cylinder block and main bearing caps. However. Remove the main bearings from the cylinder block and main bearing caps.). 6A-53 Rear Main Bearing Replacement with the graduations on the gauging plastic envelope. Install a new r e a r main bearing oil seal in the cylinder block and main bearing cap. Always replace both upper and lower insert as a unit. 9.

NOTE: Do not turn the crankshaft with the gauging plastic installed. Replace t h e main bearing upper h a l f as follows: a. Install main bearing cap with arrows pointing toward front of engine. 6A-54) b. This will roll upper bearing out of block.002" undersize for use with new and used standard size crankshafts. interference between the bearing and crankpin will result in rapid bearing failure. 3. Place a piece of gauging plastic the full w i d t h of the crankpin (parallel to the crankshaft). Install a main bearing removing the installing tool in oil h o l e in crankshaft journal. (Bearing showing the above should not be reinstalled). d. d. If the clearance exceeds specifications. .001". If within specifications and a new bearing is to be installed. a cotter pin may be bent as required to do the job.001" and . measure the maximum diameter of the crankpin to determine new bearing size required. and in . NOTE: If a bearing is being fitted to an out-of-round crankpin. replace or recondition the cranks h a f t . If the bearing is fitted to the minimum diameter and the crankpin is out-of-round . Oil new selected size upper bearing and insert plain (unnotched) end between crankshaft and indented or notched side of block. Install the bearing in the connecting rod and cap. b. Oil new lower bearing and install in bearing cap. All other crankshaft journals have oil holes. If not within specifications. select a new. remove the connecting rod cap and bearing. Rotate the bearing into place and remove tool from oil hole in crankshaft journal. Install the bearing cap and evenly torque nuts to specifications. c.using the scale on the gauging plastic envelope. bearing and remeasure the clearance. a new bearing will be required. 6A-53) c. With oil pan and oil pump removed. 4. Bearings are available in standard size and . Inspection and Replacement 1. 5. Wipe the bearings and crankpin clean of oil.L-6 Engine 6A-25 CONNECTING ROD BEARINGS Connecting rod bearings are of the precision insert type and do not utilize shims for adjustment. NOTE: If such a tool is not available. 3. 4. 5.010" and . (Fig. Inspect the bearing for evidence of wear or damage. measure the gauging plastic width at the widest point. correct size. Fig. Remove the bearing cap and . If within specifications. 6A-54 Gauging Plasfic on Crankpin b. Rotate the crankshaft clockwise as viewed from the front of engine.020" undersize for use with r e conditioned crankshafts. (Fig. If clearances are found to be excessive. Measure the crankpin for out-of-round or taper with a micrometer. Use a pair of pliers (with taped jaws) to hold the bearing thrust surface to the oil slinger and rotate the crankshaft to r e move bearing. The last 1/4" movement may be done by holding just the slinger with the pliers or tap in place with a drift punch. T o r q u e m a i n specifications. a. be sure to fit to the maximum diameter of the crankpin. Oil new selected size upper bearing and insert plain (unnotched) end between crankshaft and indented or notched side of block. DO NOT FILE RODS OR ROD CAPS. Use pliers as in removing to rotate bearing into place. 6. bearing cap bolts to 2. measure new or used bearing clearances with Plastigage or its equivalent. 6A-55) 6. c. (Fig.

install the rod cap and torque nuts to specifications. Remove connecting rod cap and install Tool J-6305 (11/32") on studs. 8. With oil pan. using remover. NOTE: If connecting rod bearings are being reused. (Fig. oil pump and cylinder head r e moved. 2. 4. If necessary. 9. Coat the bearing surface with oil. 2. place connecting rod and piston assembly in an arbor press with piston on support.. 3. Remove connecting rod bearings from connecting rods and caps. tap each rod lightly (parallel to the crankpin) to make sure they have clearance. Push connecting rod and piston assembly out of top of cylinder block. connecting rod and piston. press piston pin out of connecting rod and piston. turn crankshaft until piston is at top of stroke and remove cloth and cuttings. use a ridge reamer to remove any ridge and/or deposits from the upper end of the cylinder bore. Cleaning and Inspection Connecting Rods 1. piston pin. Inspect connecting rods and connecting rod caps for cylinder identification.6A-26 L-6 Engine Fig. between the connecting rod cap and side of crankpin. . 6A-56) CONNECTING ROD AND PISTON ASSEMBLIES Removal 1. Remove piston rings by expanding them and sliding them off the pistons. NOTE: Before ridge and/or deposits are removed. (Fig. Wash connecting rods in cleaning solvent and dry with compressed air. After ridge and/or deposits are removed. Using Tools J-9510 shown in Fig. 6A-55 Measuring Gauging Plastic Fig. then. 6A-58. Measure all connecting rod side clearances (see specifications). Remove assembly from arbor press and remove tools. mark them. place them in a rack so they may be reinstalled in their original rod and cap. Disassembly Fig. turn crankshaft until piston is at the bottom of stroke and place a cloth on top of piston to collect the cuttings. 6A-57) NOTE: It will be necessary to turn the crankshaft slightly to disconnect some of the connecting rod and piston assemblies and push them out of the cylinder. When all connecting rod bearings have been installed. 6A-56 Measuring Connecting Rod Side Clearance 7. 6A-57 Removing Connecting Rod and Piston Assemblies 3.

DO NOT WIRE BRUSH ANY PART OF THE PISTON. Clean the ring grooves with a groove cleaner and make sure oil ring holes and slots are cleaned. 2. scuffed or damaged skirts. Piston Pins Inspect piston pin bores and piston pins for wear.59) 4. eroded areas at top of the piston. Place piston on support. the piston and piston pin are a matched set and not serviced separately. wavy worn ring lands. Replace connecting rods that are damaged. . 5. Position piston on connecting rod with appropriate side of piston and oiling hole in connecting rod aligned. Inspect the piston for cracked ring lands. Because of this. 6. Pistons Clean varnish from piston skirts and pins with a cleaning solvent. If clearance is in excess of the . 6A. skirts or pin bosses. 3. Place installer on piston pin. Using Tool BT-6408. The piston pin should be measured with a micrometer and the piston pin bore should be measured with a dial bore gauge or an inside micrometer. Lubricate piston pin holes in piston and connecting rod to facilitate installation of pin.L-6 Engine 6A-27 Fig. Measure piston skirt (across center line of piston pin) and check clearance as outlined under PISTON SELECTION. Replace pistons that are damaged or show signs of excessive wear. The piston pin clearance is designed to maintain adequate clearance under all engine operating conditions. Remove installer from connecting rod and piston assembly and check piston for freedom of movement on piston pin. Piston pin bores and piston pins must be free of varnish or scuffing when being measured. start piston pin into piston and press on installer until pilot bottoms in support. Assembly 1. Inspect the grooves for nicks or burrs that might cause the rings to hang up. (Fig. indexing pilot through piston and rod.5 8 Piston Pin Removing Check for twisted or bent rods and inspect for nicks or cracks. place support w i t h spring and pilot in place on an arbor press. 6 A . the piston and piston pin assembly should be replaced.001" wear limit.

Slip the compression ring in the cylinder bore. Install piston rings as follows: (Fig. then. do so. Install oil ring spacer in groove and insert anti-rotation tang in oil hole. remove by dressing with a fine cut file.. Be sure ring is square with cylinder wall. The oil control rings are of the three-piece type. All compression rings are marked on the upper side of the ring. check a new ring. the cause should be determined and if caused by ring groove. If the pistons have not been cleaned and inspected as previously outlined. a. The top ring is chrome faced or treated with molybdenum for maximum life. press the ring down into the cylinder bore about 1/4" (above ring travel). . 5. 6A-61) to make sure that the ring is free. Select rings comparable in size to the piston being used. If binding occurs at any point. 8. consisting of two segments (rails) and a spacer. Slip the outer surface of the top and second compression ring into the respective piston ring groove and roll the ring entirely around the groove (Fig. B „ ^ " A " "D"-j\ ^ / " C " 2ND COMPRESSION RING GAP " D " TOP COMPRESSION RING GAP Fig. Fit each compression ring to the cylinder in which it is going to be used. 7. If the binding is caused by a distorted ring. 6A-59 Connecting Rod and Piston Relationship yjT f " V ps ^V. If the gap between the ends of the ring is below specifications. (Fig.6A-28 L-6 Engine Fig. 1. make sure the marked side is toward the top of the piston. remove the ring and try another for fit. 6A-61 Checking Ring in Groove Fig. 6A-62 Ring Cap Location 3. 6A-62) NOTE: Tool J-8021 (3-7/8") is available for this purpose. When installing compression rings. 2. Measure the space or gap between the ends of the ring with a gauge. 6A-60) 4. 6A-60 Measuring Ring Cap Piston Rings 6. Fig. / \ 1 " A " OIL RING SPACER GAP (Tang in Hole or Slot within Arc ) "B" Oil RING RAIL CAPS C" k .

b. the "ores should be swabbed several times with light engine oil and a clean cloth and then wiped with a clean dry cloth. Install top compression ring with gap properly located. the cause should be determined and if caused by ring groove. Hold spacer ends butted and install lower steel oil ring r a i l with gap properly located. 3. c. then ring with gaps properly located. f. (Fig. compress the rings. (Fig. Install each connection rod and piston assembly in its respective bore. Lubricate connecting rod bearings and install in rods and rod caps. Lightly coat pistons. Install second compression ring expander. (Fig. e. Therefore. rings and cylinder walls with light engine oil. Proper clearance of the piston ring in its piston ring groove is very important to provide proper ring action and reduce wear. d. With bearing caps removed. install short pieces of rubber hose over the connecting rod bolts. check a new ring. the clearance between the surfaces of the ring and groove should be measured. 6A-64 Fig. 1. If binding is caused by a distorted ring. remove by d r e s s ing groove with a fine cut file. NOTE: Be sure ring gaps are properly positioned as previously outlined. when fitting new rings. 6A-63) Installation Fig. Hold the ring compres- . Install upper steel oil ring rail with gap properly located. After cleaning. 6A-65) Guide the connecting rod into place on the crankshaft journal. Install with cylinder wall oiling hole (spit hole) in connecting rod towards camshaft. Flex the oil ring assembly to make sure ring is free. 6A-65 Installing Connecting Rod and Piston Assemblies NOTE: Cylinder bores must be clean before Piston installation. 4. If binding occurs at any point. 6A-63 Measuring Ring Groove Clearance Connecting Rod—Installed Position 2. 6A-64) Using a tool such as J-8307.L-6 Engine 6A-29 Fig. Use a hammer handle and light blows to install the piston into the bore. 9. This may be accomplished with a hot water and detergent wash or with a light honing as necessary.

Measure dimensions of main bearing journals and crankpins with a micrometer for out-ofround. NOTE: If bearing replacement is required. Check crankshaft for runout by supporting at the front and rear main bearings journals in " V " blocks and check at the front and rear intermediate journals with a dial indicator (see specifications). 5. Install rear main bearing oil seal in cylinder block and rear main bearing cap grooves. f. clutch assembly (if equipped) and flywheel. Install the crankshaft as follows: a. Remove rear main bearing oil seal and main bearings from cylinder block and main bearing caps. Remove crankcase front cover and if so equipped. 9. The numbers on the connecting rod and bearing cap must be on the same side when installed in the cylinder bore. Install crankshaft. If necessary. Remove the connecting rod caps and push the pistons to top of bores. g. Remove oil pan and oil pump. Install the bearing caps and torque nuts to specifications. 8. in solvent and dry with 6. Lubricate lip of seal with engine oil. Check the connecting rod caps for cylinder number identification. Install main bearing caps with pointing toward front of engine. 3. mount engine in overhaul stand and clamp securely. . first rearward then forward with a lead hammer. Torque rear main bearing cap bolts to 12 ft. 4. Remove main bearing caps and lift crankshaft out of cylinder block. With the engine removed from the vehicle and the transmission and/or clutch housing r e moved from the engine. If a connecting rod is ever transposed from one block or cylinder to another. beginning at the front of the engine. This will line up rear main bearing and crankshaft thrust surfaces.c. Removal 2. Wash crankshaft compressed air. hose from connecting rod 11. R e m o v e damper. Figs. Remove the spark plugs. Remove the starting motor. Install main bearings in cylinder block and main bearing caps. 3. 7. 4. SPROCKET OR GEAR REPLACEMENT Refer to TIMING GEARS . then tap end of crankshaft. e. (Force crankshaft foward and measure clearance between the front of . refer to CONNECTING ROD BEARINGS.. b. Torque all except r e a r main bearing cap bolts to specifications. Measure crankshaft end play with a feeler g a u g e . Remove the oil dipstick. Replace or recondition the crankshaft if out of specifications. Install with lip of seal toward front of engine. Retorque all main bearing cap bolts to specifications. Installation 1. mark them. 6A-48 and 6A-49 illustrate the tools used. Each connecting rod and bearing cap should be marked. CLEANING AND INSPECTION 1. being careful damage bearing surfaces. new bearings should be fitted and the connecting rod should be numbered to correspond with the new cylinder number.6A-30 L-6 Engine sor firmly against the cylinder block until all piston rings have entered the cylinder bore. Remove rubber bolts. taper or undersize (see specifications).Replacement. this surface is treated with glue. then lubricate bearing surface with engine oil. crankshaft pulley and torsional 6. d. not to arrows 1. 5. 10. Be sure to install new pistons in the same cylinders for which they were fitted and used pistons in the same cylinder from which they were removed. Keep oil off parting line surface. 2. CRANKSHAFT The crankshaft can be removed while the engine is disassembled for overhaul or without complete disassembly as outlined below. timing chain and camshaft sprocket. lbs.

When distributor shaft to bushing clearance 1. 6A-68 Replacing Distributor Bearing . This should be done with a dial indicator. Its upper diameter pilots the distributor shaft and the diameter extending below the block pilots the oil pump. may be replaced at the same time the bushing is replaced. If cylinders were found to exceed specifications honing or boring will be necessary. 4. using a 9/16 thin-wall deep socket. 6A-52. DISTRIBUTOR LOWER BEARING A N D THRUST WASHER REPLACEMENT CYLINDER BLOCK Cleaning and Inspection The distributor lower bearing is a bronze bushing pressed into the lower side of the engine block. remove valve by prying it out with a screw driver. 6A-67 Oil Filter Bypass Valve OIL FILTER BYPASS VALVE INSPECTION AND REPLACEMENT Fig. Install and seat a new valve by taping it in place. (Fig. Inspect for a cracked or broken valve.L-6 Engine 6A-31 Fig. 6A-67) the r e a r mam Dearing and the crankshaft thrust surface). out-of round or excessive ridge at top of ring travel.66) Fig. If replacement is necessary. Set the gauge so that the thrust pin must be forced in about 1/4" to enter gauge in cylinder bore. water jacket valve lifter bores and main bearing webs. Refer to Fig. NOTE: These plugs may be removed with a sharp punch or they may be drilled and pried out. (Fig. 5. where used. Measure the cylinder walls for taper. 6A-66 Measuring Cylinder Bore With the oil filter removed. install the r e maining previously removed parts. Center gauge in cylinder and turn dial to " 0 " . With crankshaft installed. 3. Some engines have a thrust washer at the upper end of the bushing bore. 2. The lower bushing will ordinarily require only a clearance or wear check during engine overhaul. Remove oil gallery plugs and clean all oil passages. h. Clean and inspect water passages in the cylinder block. Inspect the cylinder block for cracks in the cylinder walls. Carefully work gauge up and down cylinder to determine taper and turn it to different points around cylinder wall to determine the out-of-round condition. check the spring and fibre valve for operation. 6A. The thrust washer. Wash cylinder block thoroughly in cleaning solvent and clean all gasket surfaces.

Remove tool from bushing.0035". 3. Occasionally during the honing operation. When finish honing a cylinder bore to fit a piston. Before using any type boring bar. remove installer tool using slide hammer in driver bolt hole of driver handle. 6. Clean bushing bore in block and check for burrs or damage. CYLINDER H O N I N G 1. Install Tool J-9534 into bushing and using a slide hammer. free from imbedded particles and torn or folded metal. When cylinders are to be honed follow the hone manufacturer's recommendations for the use of the hone and cleaning and lubrication during honing. The cylinder should be bored to the same diameter as the piston and honed to give the specified clearance. install driver into new bushing from large inside diameter. during installation. If the cylinder block inspection indicated that the block was suitable for continued use except for out-of-round or tapered cylinders.005" taper or wear. Using a drift up through bushing bore. If more than . Position bushing and driver to block and drive the bushing in position. If this happens. It is possible that the bushing with minimum I. 6A. This is very important. 2. The finish marks should be clean but not sharp. If thrust washer was removed. they can be conditioned by honing or boring. which is determined by tool bottoming against the block. cylinder bores may be cleaned with a 3.D. start new washer in position in bore and drive into place using Tool J-9535.6A-32 L-6 Engine exceeds . . When pistons are being fitted and honing is not necessary. 3. to slightly seize the installer arbor. NOTE: This will not damage the bushing and tool is designed for this purpose should it occur. NOTE: Hone cylinders as outlined under "Cylinder Honing and Piston Fitting". the top of the cylinder block should be filed off to remove any dirt or burrs. 7. drive thrust washer (if installed) out of bore and remove from block. will collapse enough. The instructions furnished by the manufacturer of the equipment being used should be carefully followed. (Fig. REPAIRS Cylinder Conditioning The performance of the following operation is contingent upon engine condition at time of repair. Using Tool J-9535 with driver-bolt in driver handle. 6A-68) 1. CYLINDER BORING 2. it will be necessary to rebore for an oversize piston.005" wear or taper may not entirely clean up when fitted to a high limit piston. 6A-69 Cylinder Finish Marks If the cylinders were found to have less than . Fig. 1. A cylinder bore of less than. the bushing should be replaced as follows with oil pump and distributor removed. they should be bored and honed to the smallest oversize that will permit complete resurfacing of all cylinders. Permanently mark the piston for the cylinder to which it has been fitted and proceed to hone cylinders and fit the remaining pistons. the cylinder bore should be thoroughly cleaned and the piston selected for the individual cylinder checked for correct fit. After cleaning. the hone should be moved up and down at a sufficient speed to obtain very fine uniform surface finish marks in a cross-hatch pattern of approximately 45° to 65° included angle.69) 4. The piston to be fitted should be measured with a micrometer. Otherwise. 5. If it is desired to entirely clean up the bore in these cases. the cylinder bores should be swabbed several times with light engine oil and a clean cloth and then wiped with a clean dry cloth. the boring bar may be tilted which would result in the rebored cylinder wall not being at right angles to the crankshaft. 4.005" taper or wear they can be conditioned with a hone and fitted with the high limit standard size pistons. remove the bushing. measuring at the center of the piston skirt and at right angles to the piston pin. 2. hot water and detergent wash. (Fig.

Coat thread end of bolts with sealer then install bolts and torque to specifications. If cylinder bore must be reconditioned. Installation 1. If used piston is not acceptable. Scrub well with a stiff bristle brush and rinse thoroughly with hot water.L-6 Engine 6A-33 NOTE: Handle the pistons with care and do not attempt to force them through the cylinder until the cylinder has been honed to correct size as this type piston can be distorted through careless handling. It is extremely essential that a good cleaning operation be performed. Clean the remainder of the cylinder block to remove the excess material spread during the honing operation. PISTON SIZES AVAILABLE Std. FLYWHEEL Removal With transmission and/or clutch housing and clutch removed from engine. (Fig. . c. (Fig.8957" . Subtract piston diameter from cylinder bore diameter to determine "Piston to Bore Clearance". b. Clean the mating surfaces of flywheel and crankshaft to make certain there are no burrs. 2. Mark the piston to identify the cylinder for which it was fitted. 6A-72 Flywheel Installation (Typical) d.030" 3. .8780" Oversize . Check USED piston to cylinder bore clearance as follows: a. 6A-70) and determine if piston to bore clearance is in the acceptable range.8760" 3. The bores should be swabbed several times with light engine oil and a clean cloth and then wiped with a clean dry cloth.8937" 3.8760" 3.8750" 3.9037" 3.020" 3. Measure the "Cylinder Bore Diameter" with a telescope gauge (2-1/2" from top of cylinder bore). Measure the "Piston Diameter" (at skirt across center line of piston pin). measure new piston diameter (across center line of piston pin) then hone cylinder bore to correct clearance (Preferable Range). Locate piston to bore clearance on Piston Selection Chart. If any of the abrasive material is allowed to remain in the cylinder bores. it will rapidly wear the new rings and cylinder bores in addition to the bearings lubricated by the contaminated oil. Install flywheel on crankshaft and position to align dowel hole of crankshaft flange and flywheel.9057" 4. PISTON SELECTION 1. 2. the flywheel must be installed with the flange collar to transmission side. Cylinders should not be cleaned with kerosene or gasoline. remove the flywheel. 3. Fig. e thoroughly clean the cylinder bores with hot water and detergent. 3.001" 3. check Piston Size Chart and determine if a new piston can be selected to fit cylinder bore within the acceptable range. 6A-70 Piston Selection Chart MANUAL Fig. 6A-72) NOTE: On Automatic Transmission equipped engines.

Lower transmission and tighten all mounting bolts to specified torques. Broken or deteriorated mounts should be replaced immediately. 6. 5. lbs. 20 ft. lbs. Lower engine.~ Hand Tight 20 ft. lbs. washer. 30 ft. Remove crossmember to mount bolts. 25 ft. 80 in. lbs. Fig. lbs. 80 in. . 20 ft.6A-34 L-6 Engine mount through bolt. then remove stop bracket and mount from frame bracket. 4. lbs. align and start crossmember to mount bolts. 4. lbs. 2. spacer then engine TORQUE SPECIFICATIONS SIZES APPLICATION TORQUE 1/4-20 11/32-24 5/16-18 3/8-16 7/16-14 7/16-20 1/2-13 1/2-14 1n 7 ?n 14MM Camshaft Thrust Plate Crankcase Front Cover Flywheel Housing Pans Oil Pan (To Crankcase) Oil Pan (To Front Cover) Oil Pump Cover Rocker Arm Cover Connecting Rod Cap Clutch P r e s s u r e Plate Oil Pan (To Crankcase) Oil Pump Push Rod Cover Water Pump "Distributor Clamp Flywheel Housing Manifold (Exhaust to Inlet) Manifold Clamp (Outer) Manifold Clamp (All Others) Thermostat Housing Water Outlet Main Bearing Cap Flywheel Cylinder Head Temperature Sending Unit Oil Filter Oil Pan Drain Plug . 5. 30 ft. 6A-73) a r e the nonadjustable type and seldom require service. lbs. 3. lbsT 30 ft. 55 in. 115 in. 80 in. lbs. 80 in. 15 ft. lbs. 70 in. install through bolt and tighten all mount bolts to specified torques. lbs. then remove mount and spacer. Front Mount Replacement 1. lbs. lbs. lbs. lbs. lbs. 3. lbs. lbs. then install assembly on crossmember. 60 ft. . Remove mount to transmission bolts. . lbs. 20 ft. stop bracket and frame bracket assembly from crossmember. lbs. Install spacer and new mount on transmission. 6A-73 ENGINE MOUNTS Engine Mounts Engine m o u n t s (Fig. lbs. 2. lbs. Raise engine to release weight from mount. because of the added strain placed on other mounts and drive line components. Remove mount. While lowering transmission. lbs. 35 ft. 80 in. Remove nut. 125 in. lbs. 20 ft. Rear Mount Replacement 1. lbs. 55 in. Install stop bracket and new mount on frame bracket. Spark Plug . Raise transmission to release weight from mount. 95 ft. 25 ft. 10 ft. 65 ft.

Hydraulic 1..9273" .1/16" Exhaust 1/16" .0135" 2217" 2217" 1.999" .66" Lbs.5:1 1-5-3-6-2-4 3..64 @ 1. .192 @ 1. .A.000" 001" Max. .2.3/32" Stem Clearance Intake 0010" .01" Hi Limit Production + .A. PISTON RING Groove Clearance Gap Groove Clearance Gap PISTON PIN Diameter Clearance Fit In Rod CRANKSHAFT Main Journal Main Journal Main Bearing Clearance Crankshaft End Play Crankpin Rod Bearing Clearance Rod Side Clearance CAM SHAFT Lobe Lift ± . 004" Max.0032" Valve Spring Free Length 1.53" 8. 1/32" .1. Hi Limit Production + .75:1 Intake One Turn Down From Zero Lash Exhaust One Turn Down From Zero Lash Face Angle (Intake and Exhaust) 45° Seat Angle (Intake and Exhaust) 46° Seat Runout (Intake and Exhaust) 002" Max..006" 1. 001" Max.8745" .001" Hi Limit Production + .8692" 0015" Max.. 0025" Max.3.2983" .0016" (Interference) Diameter . 0085" .001" Hi Limit Production + . Approximate No.Engine Specifications 6A-35 L-6 ENGINE SPECIFICATIONS GENERAL DATA Displacement Horsepower @ rpm Torque @ rpm Bore Stroke Compression Ratio Firing Order CYLINDER BORE Diameter Out-of-Round Taper PISTON Clearance . . .2.01" 9270" . 001" Max. @ In Open 180 .2993" 001" Max.002" Journal Diameter Camshaft Runout VALVE SYSTEM Lifter Rocker Arm Ratio Valve Lash Intake Exhaust : Diameter Taper Out-of-Round 250 150 @ 4200 235 @ 1600 3-7/8" 3. . .90" Pressure Closed 56 .. 005" Max.27" Installed Height ± 1/32" 1-21/32" Damper Free Length N.8775" 002" Max. Seat Width Intake . Taper Out-of-Round 2. of Coils N. 0008" ...0027" Exhaust 0015" .8682" . 002" .001" Max.004" Max.

VALVE GUIDE REAMER CAMSHAFT GEAR REMOVAL PLATE CAMSHAFT GEAR INSTALLER CAMSHAFT GEAR REMOVER VALVE ROCKER ARM STUD INSTALLER ROCKER ARM STUD REAMER .003" O. 6 A .S.030" O.013" O.003" O.S.6A-36 Tools BT-6606 BT-6225 BT-6618 BT-6310 S-141 BT-6613 BT-6513 BT-6619 BT-6611 BT-6607 J-8614 BT-6408 BT-6614 BT-6413 BT-6612 ENGINE LIFT CHAIN COOLING SYSTEM TESTER CLUTCH PILOT BEARING INSTALLER CARBURETOR FLOAT GAUGE CARBURETOR FUEL INLET NUT WRENCH ADAPTER FOR NEEDLE AND SEAT TESTER CARBURETOR NEEDLE AND SEAT CHECKER CLUTCH PILOT BEARING REMOVER CRANKSHAFT PULLEY INSTALLER (V-8) EXH. ROCKER ARM STUD REAMER .S.015" O. VALVE GUIDE REAMER J-5830-2 .S.S. VALVE GUIDE REAMER J-5830-3 . MANIFOLD HEAT RISER BUSHING SET CRANKSHAFT PULLEY REMOVER PISTON PIN TOOLS PISTON PIN ADAPTER (L-6) VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR ADAPTER BT-6616 J-7583-3 BT-6610 BT-6601 J-5154 J-5830 CRANKSHAFT PULLEY REMOVER PILOT SCREW (USED WITH J-8614) CRANKSHAFT PULLEY AND GEAR REMOVER PLATE SCREW CRANKSHAFT TIMIJNIG GEAR AND FRONT OIL SEAL INSTALLER (L-6) J-5830-1 . DISTRIBUTOR BUSHING INSTALLER DISTRIBUTOR BUSHING REMOVER FRONT COVER CENTERING GAUGE (L-6) CLUTCH PILOT BUSHING REMOVER (L-6) FRONT SEAL REMOVER PILOT FOR TOOL BT-6406 CAMSHAFT BEARING SET J-22227 J-21795 J-8810 J-8880 J-5715 J-6036 J-9535 J-9534 J-21742 J-1448 BT-6406 J-9395 BT-6609 Fig.7 4 Tools .

engine unit numbers and engine identification is outlined in Section 0 of this manual. will be combined. 400 and 425 cu. The left bank of cylinders (as viewed from the driver's seat) are numbered (from front to rear) 1-3-5-7. in.All Series V-8 Engine 6B-1 V-8 ENGINE CONTENTS OF SECTION 6B Subject P°ge Subject Page DESCRIPTION ENGINE ASSEMBLY REMOVAL INSTALLATION ENGINE MOUNTING INTAKE MANIFOLD EXHAUST MANIFOLD MANIFOLD HEAT CONTROL VALVE. VALVE COVER ROCKER ARMS VALVE LIFTERS OPERATION ASSEMBLY AND VALVE LIFTER LEAK-DOWN TEST VALVE LIFTER DIAGNOSIS CYLINDER HEAD AND GASKET VALVES AND SPRINGS (HEAD REMOVED) MEASURING VALVE STEM HEIGHT . Drain radiator. IN. . The removal and installation of various engine parts covered in this section do not comprehend the installation of K-19 (Air Injection Reactor System). VALVE GUIDES REAMING PROCEDURE REPLACING VALVE SPRING (HEAD ON ENGINE) OIL PAN (330 & 425 CU. IN.) OIL PUMP CONNECTING ROD AND PISTON ASSEMBLY ROD BEARINGS ROD ASSEMBLY 6B-1 6B-1 6B-1 6B-2 6B-4 6B-4 6B-5 6B-6 6B-6 6B-7 6B-8 6B-8 6B-10 6B-10 6B-13 6B-13 6B-14 6B-15 6B-15 6B-15 6B-17 6B-18 6B-19 6B-19 6B-20 6B-21 PISTON MEASURING PISTON CHECKING CYLINDER BORE CLEANING PISTON RINGS RING TOLERANCE PISTON RING AND RAIL GAP SIDE CLEARANCE RING IDENTIFICATION AND INSTALLATION ROD AND PISTON ASSEMBLY PISTON PINS CRANKSHAFT PULLEY HARMONIC BALANCER FRONT COVER OIL SEAL TIMING CHAIN AND GEARS CHECKING VALVE TIMING WITHOUT REMOVING FRONT COVER CAMSHAFT CAMSHAFT BEARINGS CAMSHAFT AND OIL GALLEY PLUGS CRANKSHAFT MAIN BEARINGS REAR MAIN OIL SEAL PILOT BEARING FLYWHEEL FUEL PUMPS TOOLS SPECIFICATIONS 6B-22 6B-22 6B-22 6B-23 6B-23 6B-23 6B-23 6B-23 6B-23 6B-23 6B-24 6B-26 6B-26 6B-27 6B-28 6B-28 6B-28 6B-29 6B-30 6B-32 6B-33 6B-33 6B-36 6B-37 6B-37 6B-39 6B-40 6B-41 V . (Fig. the service procedures. . engines. unless otherwise indicated. unless otherwise specified. Cylinders in the right bank are numbered (from front to rear) 2-4-6-8. 6B-101) The required engine maintenance. The 330. it will be necessary to refer to Section 6L of this manual. Because of the similarity between the three engines. are very similar. . The engine specifications are listed at the back of this section. If the engine being serviced is equipped with K-19. . with the exception of cylinder bore size.) OIL PAN (400 CU. The illustrations used throughout this section are typical of all three V-8 engines.8 ENGINE DESCRIPTION The same basic V-8 engine is used in all series. ENGINE ASSEMBLY Removal 1.

12. 6B-102) NOTE: line. Disconnect battery. . (Fig. Disconnect exhaust pipes at manifold. Remove six bolts. transmission to engine. Be careful of vacuum modulator 13. 13. Remove engine mount through bolts and support engine. 14. Remove transmission support chain. fuel hose to fuel line. Secure Lift Chain BT-6606 to engine. On 34 through 38 Series install Engine Support Bar BT. 11. Replace three bolts. Locate engine dowels into transmission and position through bolts into mounts and tighten. 3. 5. 3. starter cable at junction block. 12. transmission to engine. Lift engine and secure transmission chain support to frame. fuel hose from fuel line. Remove three bolts. 6B-102 Engine Lift Fixture Installation 1. Use Adapters BT-6424-2. 7. converter to flywheel. 7. Remove fan blade and fan pulley. Fasten Chain BT. Replace fan pulley. fan blade.6424. Install and align hood. Lower car. heater hoses. vacuum hoses. 9. upper radiator support and coil. Replace six bolts. Lower car and remove lift chain. wiring and accelerator linkage. 11. vacuum hoses. 8. 5. Connect battery. 2. Remove Converter Holding Tool J-21654 and replace torque converter cover. 4. Reconnect radiator hoses. wiring and accelerator linkage. Raise car. On 52 through 86 Series install Engine Support Bar BT-30-16. converter to flywheel. 10. power steering pump hoses (as necessary). Disconnect radiator hoses. power steering pump hoses (as necessary). Remove torque converter cover and install Converter Holding Tool J-21654. 6B-101 Cylinder Numbers 2. 9. engine to body ground strap. disconnect Engine Support Bar and remove engine. 4. marking hinge for reassembly. engine to body ground strap. 8. heater hoses. coil and upper radiator support. 10. Fill radiator. Fig. 6. starter cable at junction block. Remove hood. Connect exhaust pipes to manifold.6B-2 V-8 Engine All Series Fig. 6.6606 to engine.

All Series V-8 Engine 6B-3 Fig. 6B-104 Engine Mounting (34. 6B-103 Engine Mounting (52 through 86 Series) Fig. 36 and 38 Series) .

then rernov manifold with carburetor attached. Remove fuel carburetor. in. 2.6B-4 V-8 Engine All Series ENGINE M O U N T I N G 7. in. Drain radiator. Disconnect throttle linkage. if car is so equipped. disconnect heater hose at rear of manifold. 6B-105 Engine O i l Flow . and vacuum lines from 1. Remove intake manifold bolts. 4. Installation Refer to Figs. Use care not to gouge or scratch machined surface. Coat both sides of gasket sealing surface that seal the intake manifold to the head with 1050026 Sealer and position intake manifold gasket. Remove air cleaner assembly. Also. Remove coil mounting bolt. 6. 6B-103 and 6B-104. Wires may be left connected to coil if desired. 6B-106. NOTE: The 400 and 425 cu. Clean machined surfaces of cylinder head and intake manifold with a putty knife. NOTE: It will be necessary to remove the distributor on 400 and 425 cu. 3. 2. power steering pump and air conditioning compressor brackets as necessary. then disconnect upper radiator hose and thermostat bypass hose from water outlet. Install end seals. Disconnect temperature gauge wire. being sure that ends are positioned under cylinder heads as shown in Fig. engines to provide removal clearance. INTAKE MANIFOLD Removal 1. 8. 9. Disconnect and/or remove generator. engines use a one-piece intake manifold gasket as 5. Fig.

disconnect the exhaust pipe. in. Dip intake manifold bolts in engine oil and torque alternately to 35 ft. R e f e r to Section 0. 4. Position intake manifold on engine and connect thermostat bypass hose to water pump. Clean manifold and cylinder head machined Showa The 330 cu. Connect temperature gauge wire. Fig. 6B-107 Intake Manifold Torque Sequence . 6B-106 Intake Manifold Gasket EXHAUST MANIFOLD Removal 1. 6B-108 shows an exploded view of the choke heat stove. PERIODIC M A I N T E N A N C E . washers and locks and remove the manifold. Straighten lock tabs and remove the manifold to head attaching bolts. spark plug wires. gaskets. FT. 3. Remove the crossover pipe (disconnect exhaust pipe if equipped with dual exhaust). 8. 6B-107) Position coil and install mounting bolt. for c o o l i n g system recommendations. engine uses two 3. 6. 4. (Fig. For the right manifold. lbs. 2.7. NOTE. throttle linkage and install air cleaner assembly. CHOKE HEAT STOVE Fig. Fig. TORQUE INTAKE MANIFOLD ATTACHING BOLTS 35 FOLLOWING THE ABOVE RECOMMENDED SEQUENCE. LBS. Connect upper radiator hose. 5. Fill cooling system. Install fuel and vacuum lines. heater hose.

6B-108 Intake Manifold Choke Heat Stove Scribing Exhaust Manifold VALVE M A N I F O L D HEAT C O N T R O L surfaces with a putty knife. Use care not to gouge or scratch machined surfaces. Installation Refer to Figs. Disconnect spark plug wires and move away from valve cover. lbs. 6B-109. Bend bolt locks to retain bolts. VALVE COVER Removal 1. Reconnect disconnected parts. ventilation 2. 6B-110 and 6B-111. 2. 3. i.6B-6 V-8 Engine All Series Fig. Disconnect positive crankcase from right valve cover. 6B-I09 Heat Control Valve Installation . 6B-110 Fig. Fig. Install manifold to head bolts and torque to 25 ft.

pivot and rocker arms. lbs. 5/16" thread 3/8" thread 25 ft. 2. lbs. lbs. 50 ft. lbs. 6B-111 Heat Control Valve Operation 3. Torque valve cover attaching screw -to 7 ft. flanged bolts. 7/16" thread ROCKER ARM ASSEMBLIES (Fig. Remove accessory mounting brackets as necessary and remove valve cover. Remove rocker arm. 6B-112 Cylinder Head Exploded View . 35 ft. NOTE: Remove each set (one set per cylinder) as a unit. Remove valve cover to cylinder head attaching screws. Fig.All Series V-8 Engine 6B-7 Fig. Installation Reverse removal procedure. Remove valve cover. 6B-112) Removal 1. For mounting brackets. torque attaching bolts as follows.

Oil is supplied to the lifter through a hole in the Fig. Install the hardened flanged bolts. 6B-114 Valve Lifter Operation side of the lifter body which indexes with a groove and hole in the lifter plunger. lbs. (Fig. through the push-rods to the rocker arms. The force of the valve spring which is exerted on the plunger through the rocker arm and push-rod causes a slight amount of leakage between the plunger and lifter body. 6B-113) 4. This "leak-down" allows a slow escape of trapped oil in the base of the lifter body. Torque Fig. As the lifter rides down the other side of the cam lobe and reaches the base circle NOTE: Both lifters should be in closed valve position when installing nuts. The plunger and lifter body then raise as a unit. 6B-114) When the lifter begins to ride up the cam lobe. 3. pushing up the push-rod to open the valve. Torque bolts to 35 ft. Position a set of rocker arms (for one cylinder) in the proper location. 6B-113 Rocker Arm Pivot Usage Installation 1. 6B-115 Valve Lifter Cutaway . Coat wear points with 1050169 Lubricant and install the pivots. VALVE LIFTERS Operation .6B-8 V-8 Engine All Series Fig. Oil is then metered past the oil control valve in the lifter. lbs. 2. the ball check is held against its seat in the plunger by the ball check spring which traps the oil in the base of the lifter body below the plunger. (Fig. bolts to 20 ft.

4. 4. 2. On varnished lifters. the plunger spring quickly moves the plunger back (up) to its original position. all parts should be cleaned in clean solvent. 1. 6B~ 116) Disassembly After lifters are disassembled. Remove intake manifold and gasket. Remove push-rod seat and oil control valve. then remove ball and spring. 2. (Fig. 6B-116 Removing Valve Lifter or "valve closed" position. Remove ball check retainer from plunger. apply carburetor cleaning solution to lifter body. If either the body or plunger is defective. A small particle of foreign material under the ball check valve will cause malfunctioning of the lifter. (See VALVE LIFTER LEAK-DOWN) Whenever lifters are removed. Available Tool BT-6438 can be used to remove plunger. This restores the lifter to zero lash. . Remove valve covers. Use of Tool BT-6407 will aid in removal of varnished lifters. NOTE: Carburetor cleaning solvent should be used in a well ventilated room. replace with a new lifter assembly. Remove plunger and plunger spring. Cleaning and Inspection NOTE: Valve lifters and push-rods should be kept in order so they can be reinstalled in their original position in the cylinder block.All Series V-8 Engine 6B-9 Fig. Avoid contact with skin and prolonged breathing of fumes. allow lifter to soak in carburetor cleaning solvent for approximately five minutes. If plunger is stuck tight. check the lifter foot for abnormal wear as follows: 1. then remove. This movement causes the ball check to open against the ball spring and oil from within the plunger is drawn into the base of the lifter. unless the leak-down rate is not within specifications. Remove lifters. burrs or scoring of parts. Remove retainer spring with Tool BT-31 or small screwdriver. 3.rods. Removal 3. rocker arm assemblies and push. Close inspection should be made for nicks. NOTE: Do not condemn valve lifters that have a slight gap or show evidence of leakage where the lifter foot is welded to the lifter body. Allow five minutes for solution to remove varnish.

Momentarily Noisy When Car is Started: 4. This condition is normal. spring over ball check 1. Hold plunger vertically to prevent cocking spring. Wear at the CENTER of the cam base circle is NORMAL. Hold plunger with spring up and insert into lifter body. fill reservoir with Hydraulic Lifter Test Fluid BT-59. Install plunger retainer.OB-10 V-8 Engine All Series 1. Lower tester ram until it contacts the steel ball. 9. then position oil control valve and push-rod seat onto plunger. (Fig. Oil drains from the lifters which are holding the valves open when the engine is not running. 13. NOTE: Lifter foot must be clean and dry. Position the 1/4" steel ball on the push-rod seat. allow ram to bleed down lifter until retaining groove is exposed. 6B-118 Valve Lifter Bleed Down Test . Assemble ball check and retainer into plunger. then allow to lower as in Step 7 Repeat this procedure several times or until all air is expelled from lifter. 12. Allow ram to move downward by its own weight until air bubbles disappear. Place assembly into the tester cup. 6B-117) Make sure retainer flange is pressed tight against bottom of recess in plunger. The camshaft should be replaced ONLY when wear is present across FULL WIDTH of cam base circle. then.59 and leak-down tested before placing into service. the lifter should be replaced and the camshaft inspected for wear. If leak-down tolerance is within specifications. 1. 3. 8. 5. 6B-117 Valve Lifter Exploded View Fig. Rotate reservoir one revolution every two seconds and time the indicator from the start to the stop line. 2. Raise arm. Place a straight edge across the lifter foot. check for light between the straight edge and lifter foot. NOTE: Do not attempt to expell air from lifter by pumping on ram. 11. 10. Assembly and V a l v e Lifter Leak-Down Test NOTE: Lifters must be assembled while submerged in Hydraulic Lifter Test Fluid BT. 6. Install Adapter 105-2 in reservoir of Tester BT-60. the lifter can be placed in service without removing test fluid. If light indicates a flat or concave surface of the lifter foot. 6B-118) Allowable leak-down rate is six seconds minimum for used lifters and 9 to 60 seconds for new lifters. 3. V a l v e Lifter Diagnosis 2. 1/2" below top of reservoir. It will take a few seconds for the lifter to fill after the engine is started. (Fig. 7. After all air is expelled. Adjust ram screw so that it contacts the steel ball in the push-rod seat when the pointer is at the start line. then start test by resting ram on steel ball. Install retaining ring. Fig. While holding the lifter at eye level. Raise ram.

(Fig. See PERIODIC MAINTENANCE Section. Replace as required. This noise is not connected with lifter malfunction. It is necessary to determine which are actually responsible for the noise. 2. a. (5) Off square rocker arm pad. replace spring. Repeat until valve becomes quiet. Observe rocker arm pad for excessive wear or excessive off square. If noise momentarily disappears and then re-appears after a few seconds with the feeler still inserted. Correction: The lifter must be replaced. With gloved hand. It is caused by one or more of the following: (1) Badly worn or scuffed valve tip and rocker arm pad. Low oil level . a. Correction: Clean the lifter and inspect. b. Noise will change. replace lifter. it is an indication that the lifter leak-down rate is too fast. either becoming louder or disappearing completely. 6B-120) . Noisy at High Car Speeds and Quiet at Low Speeds. push sideways on valve spring. it may be entirely gone or appear as a light ticking noise in one or more valves. 6B-119 Valve Spring Checking valve stem to guide (3) Excessive valve seat runout. It becomes most noticeable in the car at 10 to 15 mph " L " range.Oil level above the " F u l l " mark allows crankshaft counterweights to churn the oil into foam.015" feeler gauge between the rocker arm and valve stem. Correction: Drain oil until proper level is obtained. If spring is off square more than 1/16" in free position. locate noisy valves by increasing engine speed slightly above idle. or 30 to 35 mph " D " range and is best described as a hashy sound. When foam is pumped into the lifters. a. Rotate spring. Correction: 4. Quiet With Cold Oil or As Engine Speed is Increased: Insert a . Noisy At Slow Idle or With Hot Oil. check for an off square valve spring. Some noise will be present in all valve locations. about 1500 rpm. 3. or it may be caused by dirt. damper clicking on (8) Distorted lock plate. Noisy at Idle Becoming Louder as Engine Speed is Increased to 1500 rpm. (Fig. (6) Excessive valve face runout. 6B-119) b. If ball is defective. Fig. 5. High oil level . (2) Excessive clearance. Intermittently Noisy on Idle Only.Oil level below the "Add" mark allows the pump to pump air at high speeds which results in noisy lifters. Disappearing When Engine Speed is Increased: Intermittent clicking may be an indication of a flat or pitted ball. Occasionally this noise can be eliminated by rotating the valve spring and valve. See PERIODIC MAINTENANCE Section.All Series V-8 Engine 6B-11 Correction: Fill until proper oil level is obtained. This will also rotate valve. Remove valve covers and while listening with a stethoscope. If correction is obtained. Crank engine until noisy valve is off its seat. (7) Valve spring retainer. they will become noisy since a solid column of oil is r e quired for proper operation. (9) Two barrel engine push-rod in a four barrel engine. At slow idle. (4) Off square valve spring.

If this method does not quiet the lifter. b. Excessive wear of the spherical surface indicates one of the following conditions. Lifter should be replaced.027" longer than two barrel 330 cubic inch engine push-rods and are identified by a blue band at each end. If valve lash is present. 6B-121. Install manifold gaskets and manifold. washers and nuts on cylinder head as shown in Fig. trouble is in the lifter. (4) Defective lifter. If correction is not obtained. Position rocker a r m s . Observe upper end of push-rod. The push-rod and rocker arm must be replaced. 6. Install lifters and push-rods into original position in cylinder block. Improper hardness of the push-rod ball. Improper lubrication to the push-rod. If necessary. If valve lash exists and push-rod and rocker arm are okay. 6B-121 Fig. 6B-120 Rocker Arm Wear Baffle Installation Checking of the above four items: Remove the rocker arm assemblies then proceed as follows: 1. 3. 2. Install baffle (if removed) in 400 and 425 cubic inch engines as shown in Fig. a. 1. 3. (3) Lifter plunger stuck in down position due to dirt or varnish. pivots. This condition can be caused by foreign particles or excessive valve lash. the push rod can be freely moved up and down a certain amount with rocker arm held against valve. Check for valve lash by turning engine so the piston in that cylinder is on top dead center of firing stroke. Installation c. Valves Noisy Regardless of Engine Speed. correct as required. Correction a. The oiling system to the push-rod should be checked.6B-12 V-8 Engine All Series Fig. b. check for excessive valve stem to guide clearance. lock plates. (2) Worn rocker arm. . 2. Valve lash indicates one of the following: (1) Worn push rod. With transmission in NEUTRAL and parking brake on. This method of correction has proven successful for dislodging a foreign particle which is preventing the ball from seating properly. The push-rod and rocker arm must be replaced. If push-rod appears in good condition and has been properly lubricated. strike the rocker arm above the push-rod with a mallet while the engine is idling. 6B-121. run the engine at a high speed. NOTE: Four barrel 330 cubic inch engine push rods are . replace rocker arm and recheck valve lash.

Ail Series

V-8 Engine

6B-13

NOTE: Loosen or remove any accessory brackets which interfere. 5. Remove ground strap from head. right cylinder

6. Remove cylinder head bolts and remove cylinder head with exhaust manifold and rocker arms attached. NOTE: DO NOT BEND OIL DIP STICK TUBE WHEN REMOVING OR INSTALLING LEFT CYLINDER HEAD.
Installation

Head gasket should be coated on both sides with Part No. 1050026 Sealer or equivalent before installation. Clean and dip entire cylinder head bolts in engine oil. Torque head bolts to 80 ft. lbs. (Fig. 6B-123) and torque exhaust manifold to head bolts to 25 ft. lbs. Bend exhaust manifold bolt locking tabs.
Fig. 6B-122 Cylinder Head Exploded View VALVES A N D SPRINGS (HEAD REMOVED)

4. Install intake manifold and valve cover, connect spark plug wires and install air cleaner.

CYLINDER HEAD AND GASKET
Removal

NOTE: Valves used in Starfire and 400 cu. in. engines are .030" longer than other V-8 valves and are identified as shown in Fig. 6B-124.
Removal

1. Drain radiator and cylinder block. 2. Remove intake manifold. 3. Disconnect exhaust crossover pipe for left side and/or crossover pipe and exhaust pipe for right side. 4. Remove valve cover.

1. Remove spark plugs and exhaust manifold. 2. Remove valve keys by compressing valve spring with a tool such as J-7541 or OTCCF-11. 3. Remove valve spring retainers and springs. 4. Remove oil deflectors from valve stems.

Fig. 6B-123

Cylinder Head Torque Sequence

6B-14

V-8 Engine

All Series

TYPE INTAKE . .-. - - ^ ^ms^ i
t

ENGINE USAGE 330 CU.IN. 400 CU. I N .

PAINT CODE YELLOW RED

FORGED HEAD LETTER DIA. "01" "SI" "04" "S4" "07" "S7" "06" "S6" "El" "Tl" "E2" "T2" "E3" "T3" 1.875 2.062 2.000 2.000 1.562 1.625 1.625

LENGTH 4.620 4.593 4.563 4.593 4.620 4.557 4.587

SEAT ANGLE

45° 30° 30° 30° 45° 45° 45°

INTAKE INTAKE INTAKE EXHAUST

425 CU.IN. GREEN (Exc. Starfire) 425 CU. IN. (STARFIRE) 330 CU.IN. BLACK YELLOW

e *>

^

EXHAUST EXHAUST

425 CU 0 IN. GREEN (Exc. Starfire) 400 CU. I N . 425 C U . I N . (STARFIRE) BLACK

Fig. 6B-124 Valve Identification

5. Remove valves. Keep valves separated so they can be installed in their original locations. (Fig. 6B-125)
Installation

1. Install valves in their respective guides. 2. Install new oil deflectors Position deflectors down as valve stem. The deflectors sition themselves when the 3. Position valve over valve stem. far as possible on will correctly poengine is started. stems.

clean carbon from cylinder heads and valves using care not to gouge or scratch machined surfaces. A soft wire brush is suitable for the purpose. Whenever valves are replaced or new valves installed, the valve seats must be reconditioned. If valve guide bores are worn excessively, they can be reamed oversize. This will require replacement of the valves. The guide bores should be reamed before grinding the valve seats. Valve clearance in guide bore should be .001" to .004".
Measuring Valve Stem Height

springs over valve

4. Install valve spring retainers; then, compress springs with a tool such as J-7541 or OTCCF-11 and install valve stem keys. 5. Check valve springs and keys to be sure they are properly seated. 6. Install exhaust manifold. Torque bolts and nuts to 25 ft. lbs. Bend exhaust manifold bolt lock tabs. 7. Set spark plug gap (.030"). Lubricate plug threads with one drop of SAE 10W30 oil and re-install plugs. Torque to 35 ft. lbs.
Reconditioning Valves

Whenever a new valve is installed, or after grinding valves, it will be necessary to measure valve stem height as follows:

When reconditioning valves and valve seats,

Fig. 6B-125

Valve Location

All Series

V-8 Engine

6B-15

Fig. 6B-127 Measuring Valve Retainer Height Fig. 6B-126 Measuring Valve Stem Height

Install Gauge BT-6428 as shown in Fig. 6B-126. There should be at least .035" clearance (on all except Starfire and 400 cu. in. engines which have a clearance of at least .005") between gauge surface and end of valve stem. (Valve stem can be gauged with or without the valve spring r e tainer on the valve.) If clearance is less than specifications, remove valve and grind tip of valve stems as required on a valve refacing machine using the " V e e " block attachment to insure a smooth 90° end. Also be certain to break sharp edge on ground valve tip. Observe an original valve to determine chamfer. After all valve keys have been installed on valves, tap each valve stem end with a hammer to seat valve retainers and keys. Using Gauge BT-6428 as shown in Fig. 6B-126 and Fig. 6B-127, re-gauge all valves between valve stem and gauge and valve retainer and gauge. If any valve stem end is less than .030" above retainer, the valve is too short and a new valve must be installed. EXAMPLE: Valve Retainer to Gauge Clearance Minus Valve Stem to Gauge Clearance This is less than .030" and a new valve should be installed.
VALVE GUIDE BORES

If a standard valve guide bore is being reamed, use the .003" or .005" oversize reamer. For the .010" oversize valve guide bore, use the .013" oversize reamer. If too large a reamer is used and the spiraling is removed, it is possible that the valve will not receive the proper lubrication. Occasionally a valve guide bore will be oversize as manufactured. These are marked on the inboard side of the cylinder heads on the machined surface just above the intake manifold surface, Fig. 6B-128. These markings are visible without removing any parts other than the air cleaner assembly. Before removing the cylinder heads to perform service to either the valves or valve guide bores, the cylinder heads should be inspected to determine if these markings are present. If no markings are present, the guide bores are standard. If oversize markings are present, any valve replacement will require an oversize valve. Service valves are available in five different stem diameters: Standard, .003" oversize, .005" oversize, .010" oversize, and .013" oversize.

.060" .035" .025"

REAMING PROCEDURE

Before attempting to ream the valve guide bores they should be cleaned using Tool BT-6415 as shown in Figure 6B-129. This procedure to ream valve guide bores using Tool BT-6414 is shown in Fig. 6B-130. Use care to hold reamer straight in valve guide bore.
REPLACING VALVE SPRING (HEAD O N ENGINE) (Fig. 6 B - 1 3 1 )

As previously stated, if the valve guide bores are worn excessively, they can be reamed oversize. The following reamers are available: BT-6414-1 .003" Oversize Valve Guide Reamer BT-6414-4 .005" Oversize Valve Guide Reamer BT-6414-3 .013" Oversize Valve Guide Reamer

To replace a worn or broken valve spring without removing the cylinder head proceed as follows:

6B-16

V-8 Engine

All Series

Fig. 6B-130

Reaming Valve Guide Bore

sible, then remove keys, spring retainer cups and springs. NOTE: If valve spring does not compress, tap tool with a hammer to break bind at retainer and keys.
Installation

Fig. 6B-128

Valve Guide Bore Marking

Removal

1. Remove rocker arm assemblies. 2. Remove spark plug and install Tool BT-721-B into spark plug hole and attach to an air hose to hold the valve against its seat. 3. Install Tool BT-6413, (Fig. 6B-132) compress the valve spring until valve keys are acces1. Install valve spring and spring retainer. Using Tool BT-6413 compress the valve spring until the valve keys can be installed. 2. Install spark plugs. Torque 35 ft. lbs. 3. Install rocker arm assemblies.

Fig. 6B-129

Cleaning Valve Guide Bores

Fig. 6B-131

Removing Valve Spring

Hoist the car and drain oil. Part No. 6. 3. 36 and 38 Series) Disconnect exhaust pipe from right exhaust manifold. Install front and rear seal (rubber). 1050169.1 3 3 ) Fig. b. in. a. 6B-132 Valve Spring Tool OIL PAN ( 3 3 0 and 4 2 5 cu. 3. Remove crossover pipe and starter. NOTE: Be sure distributor does not contact cowl and fan blades do not contact fan shroud. (34. Disconnect engine mounts and jack front of engine up as far as possible using Engine Support Tool BT-6501. Installation (Fig. Remove oil pan attaching bolts and remove oil pan. Remove the dip stick. Torque 5/16" bolts to 15 ft.All Series V-8 Engine 6B-17 2. on seal area and install pan. 6 B . 2. Removal 1. Position No. 5. (52 through 86 Series) Lower relay rod by disconnecting idler arm or pitman arm. Apply 1050026 Sealer to both sides of pan gaskets (cork) and install on block. 1 crankshaft throw up. Fig. Wipe Lube.) 1. 6B-133 O i l Pan Installation . 4.

2. and 1/4" bolts to 10 ft. 9. lbs. 6B-134 Oil Pump Exploded View lbs. 3. between upper and lower right hand mounts. Position fork of tool to lift pulley hub. 2 connecting rod journals should be at 4 or 7 o'clock position as viewed from front of engine. Disconnect right hand engine mount. in. Installation ( 4 0 0 cu.6B-18 V-8 Engine All Series Fig. 7. using the left engine mount as a pivot. Raise right side of engine approximately 2-1/2" and insert block ToolJ-21662-1. Use Tool BT-6501-3 to raise front of engine. in.) NOTE: Remove the lower two right hand engine cover bolts to permit Tool BT-6501-3 to clear the water pump outlet. Install Tool BT-6424-1 Engine Support Bar and insert a 1" block between tool and right rear corner of oil pan to obtain additional lift on right side. 1 and No. Removal 1. engines for gasket sealing and reverse the r e moval procedure. Remove upper radiator baffle. 4. DO NOT BOLT TOOL TO BLOCK since engine must rock when raised. Remove drive shaft. transmission and flywheel. Fill crankcase as explained in the PERIODIC MAINTENANCE Section. Remove Engine Support Bar Tool BT-6424-1 from rear of engine. 8. Remove oil pan attaching bolts and remove oil pan toward rear of engine. Disconnect "Neg" battery cable. in. .) Refer to oil pan installation 330 and 425 cu. OIL PAN ( 4 0 0 cu. 6. Disconnect left exhaust pipe and starter. transmission crossmember. 5. NOTE: It is necessary to raise both the front and r e a r of the engine and tilt it to the left. NOTE: No.

R e m o v e Removal) oil pan. (Fig. Remove the drive gear and idler gear from the pump body. Remove the oil pump cover attaching screws and remove the oil pump cover and gasket. then install the idler gear. NOTE: Do not attempt to remove the washers from the drive shaft extension. cup. Remove the cotter pin. Remove the oil pump drive shaft extension. Position pump onto the r e a r main bearing cap and install attaching bolts. 3. then install the spring cup and retaining pin. Install the drive gear into the pump with the hex ID of the drive shaft toward the oil pump mounting pad. If they are damaged. 3. Inspection 1. Proper end clearance is . Refer Installation. lbs.0025" to . Torque bolts to 35 ft. 2. Remove the oil pump to rear main bearing cap attaching screws. (Fig. Install the oil pan.0025" to . the gear end clearance should be gauged. 4. 1. The drive shaft extension and washers must be serviced as an assembly.0050". NOTE: When assembling the drive shaft extension to the drive shaft. spring and the pressure regulator valve. Proper CONNECTING ROD AND PISTON ASSEMBLY Removal 1. Position the pressure regulator valve into the pump cover. 6B-135 O i l Pump Drive Shaft Extension Fig. NOTE: Position thumb over pressure regulator bore before removing cotter pin. Installation Disassembly (Fig. 6B-136 O i l Pump Installation OIL PUMP Removal valve to bore clearance is Assembly . Position a new gasket on the pump body and install the oil pump cover. then remove pump and drive shaft extension. new gears should be installed. lbs. During assembly. as the spring is under pressure. 1.0065". 6 B .1 3 4 ) 1. to OIL PAN - Check the gears for scoring or other damage. 6B-135) 2. . (Refer to OIL PAN- 2. closed end first. Also check the pressure regulator valve. 6B-136). Tighten the cover screws to 8 ft.All Series V-8 Engine 6B-19 Fig. 3. 2. valve spring and bore for damage. Insert the drive shaft extension through the opening in the main bearing cap and block until the shaft mates into the distributor drive gear. the END OF THE EXTENSION NEAREST THE WASHERS MUST BE INSERTED INTO THE DRIVE SHAFT. head or heads. Remove intake manifold.

Install guide hose over threads of rod bolts. If the pistons are to be removed from the connecting rod. Remove oil pump assembly. . 6B-138 Bearing Tang and Notch 2. Remove other rod and piston assemblies in the same manner. Burrs may be removed with a fine oil stone. The connecting rod journals can be checked for out-of-round with the use of a micrometer. 5. 3. If ridge exists. Examine the cylinder bore above ring travel. If the journals are scored or ridged. Clean oil from journal bearing cap. left bank 1-3-5-7. 4. the crankshaft must be replaced. Adjustment for wear is compensated by replacing the bearing. Remove bearing cap and determine bearing clearances by comparing the width of the The connecting rod bearings are assembled with a slight projection above the rod and cap faces to insure a positive contact. 6B-137) 6. The right bank is numbered 2-4-6-8. 3. lbs. Inspect journals for roughness and wear. (Fig. 7. Maximum out-of-round must not exceed . Remove rod and piston assembly through the top of the cylinder bore. 6B-137 Connecting Rod Bolt Guide Fig. 7. NOTE: Stamp cylinder number on the machined surfaces of the bolt bosses of the connecting rod and cap for identification when reinstalling. Remove oil pan. With connecting rod journal at the bottom. Position insert so that tang is properly aligned with notch in rod and cap. (Fig.0015". NOTE: It may be necessary to remove oil pump to provide access to r e a r connecting rod bearings.6B-20 V-8 Engine All Series Fig. Connecting rod bearings can be replaced without removing the rod and piston assembly from the engine. ROD BEARINGS 1. 6B-138) 6. Remove oil pan. stamp cylinder number on machined surfaces of connecting rod and cap for identification when reinstalling. 2. 4. Slight roughness may be removed with a fine grit polishing cloth saturated with engine oil. Reinstall bearing cap and torque to 42 ft. connecting rod and outer and inner surface of bearing inserts. NOTE: Refer to ENGINE SPECIFICATIONS Chart at the back of this section. mark cylinder number on piston with a silver pencil or quick drying paint. If plastigauge is to be used: 5. Remove rod bearing cap and bearing. This is to prevent damage to bearing journal and rod bolt threads. Place a piece of plastigauge in the center of lower bearing shell. remove ridge with ridge reamer before attempting to remove the piston and rod assembly. then remove caps. 8.

6B-139) If this clearance is greater than . (Fig. 9. Repeat Steps 2 through 7 on remaining connecting rod bearings.0035". FLATTENED . NOTE: Lubricate bearing with SAE 10W30 oil before installation. Measure the rod side clearance as shown in Fig. 6B-139 Checking O i l Clearance Fig. PLASTIGAUGE.All Series V-8 Engine 6B-21 . a new rod must be Fig. R O D ASSEMBLY If a rod is twisted or bent. The number within the graduation on the envelope indicates the clearance in thousandths of an inch. All rods must be connected to their journals when rotating the crankshaft to prevent engine damage. 6B-141 Piston Identification . 6B-140. Fig. 6B-140 Connecting Rod Side Clearance flattened plastigauge at its widest point with the graduation on the plastigauge container. replace the bearing and recheck clearance with plastigauge.

(Fig. 6B-142) NOTE: Refer to ENGINE SPECIFICATIONS Fig. NO ATTEMPT SHOULD BE MADE TO STRAIGHTEN CONNECTING RODS. at 90° to the normal piston pin location. Each piston should be fitted to its individual cylinder and marked for that cylinder. 6B-141) MEASURING PISTON NOTE: Refer to ENGINE SPECIFICATIONS Chart at the back of this section.005" or .6B-22 V-8 Engine All Series When measuring piston for size or taper. These pistons will be either . Insert piston with pin and rings removed. 2. When replacing pistons.001". oversize pistons may be found. The reading should be between 3 to 12 pounds while pulling the feeler gauge out of the bore. slowly pull the scale in a straight line and note the reading on the scale. 1. NOTE: On some c a r s . the largest reading must be at the bottom of the skirt. The piston and cylinder bore must be free of oil and at the same temperature. measurement must be made on skirt 90° from piston pin hole (with the piston pin removed). into bore with head downward. 6B-144 Piston Rings . Allowable taper is . 6B-142 Cylinder Bore Marking installed. 6B-143) Fig. the original cylinder size is stamped with a code letter on the block near each cylinder on the cylinder head surface. Attach Scale J-5515 to feeler gauge.010" oversize.0015" feeler gauge against the upper side of the bore. 3. While holding the piston in the center of its normal travel. (Fig. When measuring taper. 6B-143 Checking Piston Clearance Fig. CHECKING CYLINDER BORE PISTON (Fig. Place a strip of .000" to .

6B-145) If the gap measurement is less than . file the ends of rings and rails until the minimum gap is obtained.010".020" for compression rings and . 6B-145 Measuring Piston Ring Gap Fig. CLEANING PISTON the ring or rail positioned squarely and at the bottom of the ring-travel area of the bore. 6B-146 Piston Ring Side Clearance . 6 B . 6 B . 6B-146) The piston grooves must be cleaned before checking ring for side clearance. Ends of rings and rails must be filed square. The oil rings consist of two rails and an expander.001" taper. the oil rings must be installed on the piston. Deposits in the ring grooves should be removed with a suitable ring groove cleaning tool.010" to . NOTE: To check oil ring side clearance. The most wear will occur at the top of the ring travel. It is important that reconditioned cylinder bores be thoroughly washed with a soap and water solution to remove all traces of abrasive material to eliminate premature wear. minimum. ROD A N D PISTON ASSEMBLY When installing new rings. Break sharp corners after filing. Maximum allowable taper of the cylinder bore is . Ring Tolerances RING IDENTIFICATION A N D INSTALLATION (Fig.055" for oil rings. Reconditioned cylinder bores should be held to not more than . (Fig.1 4 4 ) 0001" to . Each ring must be checked for side clearance (see chart) in its respective piston groove by inserting a feeler gauge between the ring and its upper land. ring gap and side clearance should be checked as follows: Piston Ring and Rail Gap Installation Each ring and rail gap must be measured with 1. Side Clearance Clean the pistons by scraping carbon off the top of the piston.All Series V-8 Engine 6B-23 Chart at the back of this section. refer to the instructions furnished with the parts package. Install connecting rod bolt guide hose over Fig.0038" The pistons have three rings (two compression rings and one oil ring).015" to . ALLOWABLE SIDE CLEARANCE Oil Rings Compression Ring RINGS (Fig.001" out-of-round and .0051" 0018" to . Cylinder bore size can be measured with inside micrometers or a cylinder gauge. (Fig. It is important that the ring grooves be completely free of deposits.1 4 7 ) NOTE: For service ring specifications and detailed installation instructions.

PISTON PINS The correct piston pin fit in the piston is .0003". 6B-148) 2. 6B-149 Piston Ring Compressor rod bolt threads. the connecting rod cap attaching nuts should only be tightened enough to keep each rod in position until all have been installed. If the pin to piston clearance is to the high limit (. Apply SAE 10W30 oil to rings and piston. Lubricate the crankshaft journal with SAE 10W30 oil and install connecting rod bearing and cap.0005").0003" to . (Fig.6B-24 V-8 Engine All Series Fig.002" to . when checked with a feeler gauge on each crankpin. The clearance between the adjacent rods. Fig. then install piston ring compressing tool on piston. 6B-150) 5. It is important that the piston pin hole be clean and free of oil when checking pin fit. the pin can be inserted in the piston with very little hand pressure and will fall through the piston by its own weight. 6B-147 Piston Ring Identification Fig. 6B-150 Connecting Rod Side Clearance . NOTE: When more than one rod and piston assembly is being installed. should be from . lbs. 6B-149) 3.011". the pin will not fall through.0005" loose. 6B-148 Connecting Rod Bolt Guides Fig. Install assembly in its respective cylinder bore so notch cast in top of piston is towards the front of engine. (Fig. with bearing index tang in rod and cap on same side. This will facilitate installation of remaining piston assemblies. ( F i g . If the clearance is . 4. Torque rod bolt nuts to 42 ft. The pin is a press fit in the connecting rod.

2. Place piston on piston pin remover Tool BT-6408-1. 6B-151. 6B-153 Piston and Connecting Rod Assembly . 6B-152 Tool BT-6408 Whenever the replacement of a piston pin is necessary. and press pin out. with the letter " F " on piston facing up. use the following procedure. Removal 1. Place Remover Tool BT-6408-3 in piston pin as shown in Fig. 6B-151 Removing Piston Pin Fig.All Series V-8 Engine 6B-25 Fig. Fig.

6B-156 Installing Harmonic Balancer 3. 6B-152) 2. Coat piston with SAE 10W30 oil. in. 3. Place piston on Tool BT-6408-1 with letter " F " facing up. Place pin in piston as shown in Fig. engines. 2. 6B-155 Removing Harmonic Balancer 1. 3. 6B-154. Tool BT-6408-5. Installation 1. and Guide Stop Tool BT-6408-2 in main body Tool BT-6408-1. 1. Removal Fig. Install fan pulley and fan. 6B-153 for correct rod and piston assembly. Remove belt(s) and fan. Refer to Fig. Remove belts. fan. Fig. BT-33-70M. Install pulley. lbs.6B-26 V-8 Engine All Series Fig. This will automatically center the pin in the piston.0008" to . Place spring. and four bolts. 2. Install belt(s). Remove four pulley bolts and pulley. P r e s s in piston pin with Tool BT-6408-3 until it makes contact with Guide Stop Tool BT-6408-2 in Main Body Tool BT-6408-1. fan pulley and crankshaft pulley.0016" tight. Adjust belts using Tool HARMONIC BALANCER NOTE: A harmonic balancer is used in place of the pulley hub on all except two barrel low compression 330 cu. (Fig. Hoist car. 6B-154 Installing Piston Pin CRANKSHAFT PULLEY Removal Installation 1. . Torque to 20 ft. Pin to connecting rod fit is .

Use Tool 3. 1050169. timing pointer and water . Installation FRONT COVER 1. Install pulley and belt(s). 6B-159 Front O i l Seal Installation pulley hub and to crankshaft key to prevent possible oil leakage. Install front cover. 2. remove balancer as shown in Fig. crankshaft pulley. 4. timing pointer and water pump assembly. 6B-158 Front O i l Seal Removal 2. 6B-155. Apply 1050026 sealer to gasket around water holes and place on block.All Series V-8 Engine 6B-27 Fig. 2. Fig. Remove all belts. and pulley hub. 6B-157) Installation 1. Apply 1050026 Sealer to inside diameter of Removal 1. Remove washer.001 tight to . (Fig. 6B-157 Engine Front C o v e r Bolts 2. Install new cover gasket. 3. 6B-156) F i g . 4. 5. Remove cover to block attaching bolts and remove cover. Coat outside area of crankshaft pulley hub which enters seal with Special Seal Lubricant. Torque 160 ft. and both radiator hoses. bypass hose. Remove oil pan.0007 loose. harmonic balancer hub bolt and NOTE: Balancer to crankshaft fit is . Install washer and bolt. Using balancer puller. lbs. Part No. (Fig. fan and fan pulley. BT-33-70M and adjust. Install harmonic balancer on crankshaft. Drain cooling system. Disconnect heater hose. 3.

Remove oil slinger. 6B-161 Fuel Pump Eccentric . Install and adjust belts. 3. lbs. install oil seal as shown in Fig. crankshaft gear. Torque bolts to 20 ft. (Fig. Fill radiator and crankcase. 3. Torque bolts evenly as indicated. Using Tool BT-6405. Remove fuel pump eccentric. 2. lbs. Install the pulley hub and crankshaft pulley. 6B-161) 3. Fig. chain and cam gear. Installation 11. Using Tool BT-6406. 4. Install fan pulley. Torque to 20 ft. right valve cover. (Fig. 6. 1. 3. Remove the belts. Remove the crankshaft pulley and pulley hub. and adjust using Tool 1. Install camshaft gear. Install oil pan. Remove distributor cap. Apply Lubricant 1050169 on pulley hub seal surface. 6B-159. and align timing marks. 6B-158. Apply SAE 10W30 oil to bolts (threads and heads) and install. 7. 2. Install pulley hub and pulley hub bolt. remove oil seal shown in Fig. Install b e l t s BT-33-70M. Torque 160 ft. 6B-160) 2. 4. OIL SEAL Removal (Front Cover Installed) 1. 6B-160 Timing Gear Position Fig. 9. Install crankshaft pulley and four attaching bolts. bypass hose and radiator hoses. as CHECKING VALVE T I M I N G WITHOUT REMOVING FRONT COVER 1. fan and four attaching bolts. TIMING CHAIN AND GEARS (With Front Cover Removed) Removal 8. Installation 1. 5. crankshaft gear and timing chain together. 10. 2. Install fuel pump eccentric with flat side rearward.6B-28 V-8 Engine All Series pump assembly. Apply 1050026 Sealer to outside diameter of seal. Connect heater hose. lbs. Install oil slinger.

Continue to turn engine until timing mark on crank pulley is aligned with 0 on indicator. 8. Crank engine until rotor approaches No. 8. Remove front cover. 1 piston will be at the top of the cylinder. 6. 4 piston will be at the top of the cylinder. 3 Turn ignition switch on. 7. 4. Ground coil wire to engine. (Fig. 6. 2. Measurement should be approximately 3/16" more than the first measurement. 6B-162) 7. 4. Installation NOTE: To insure proper camshaft installation Fig. Remove radiator. Measure from pivot boss on head surface to top of push rod. No. 4 intake and exhaust rocker a r m s and pivot. Remove camshaft by carefully sliding it out the front of the engine. 6B-162) 5. 6B-162 Checking Valve Timing . Remove intake manifold. Remove fuel pump. (No. (No. Remove rocker arm assemblies. 6B-163) Removal 1.¥ All Series V-8 Engine 6B-29 No. 4 intake valve) (Fig. timing chain and gears. air conditioning condenser and front end sheet metal as necessary. 3. No. push-rods and valve lifters. 2. See illustration for retarded and advanced dimensions. CAMSHAFT (Fig. 4 intake valve) Record measurement. This should be top dead center. Slowly turn engine until rotor approaches No. 5. 4 spark plug wire position. Again measure from pivot boss surface to top of push rod. Remove oil slinger. Remove distributor. Continue to turn engine until timing mark on crank pulley is aligned with 0 on indicator. 1 spark plug wire position.

& 1.-A. 4. S.24105 . Install camshaft CAREFULLY. AoT.416 1.482 1.372 1. 1.472 1.-S. Refer to ELECTRICAL Section.28888 .26880 Q o 6 400 CU. When installing the bearings. IN.29419 . 2BBL 1.416 1.27080 .426 1. 6B-163 Camshaft Identification and to provide initial lubrication. INTAKE EXHAUST CAM LIFT INTAKE EXHAUST 330 CU. All bearings must be removed before any can be installed.362 .26745 .414 .29419 425 CU.T.M. IN.424 1.414 .362 1. (STARFIRE) 1.29619 . Install fuel pump. 330 CU. Install radiator. Install distributor.424 1. push-rods and rocker arm assemblies and valve covers. . 2 and 1. 3.26945 . then 3. 1. 3.26880 Fig. Install valve lifters. Number 1 bearing must be removed first.388 1.416 1.M.29419 .372 1. 1. CAMSHAFT BEARINGS 2. Install intake manifold. Part No.372 1. IN.414 .426 1. 6.424 1. IN.426 1.24362 . oil slinger and front cover.27080 .26945 . 1. then number 4. Install timing chain and gears.24305 . IN.27080 .482 1.6B-3Q V-8 Engine All Series END VIEW OF CAMSHAFT ENGINE USAGE BASE CIRCLE DIA.29619 . The camshaft bearings must be replaced in complete sets.28688 400 CU.24162 0 0 ^<-_—-^ 330 CUo IN 4BBL.26745 . 7. 582099.29400 . 4BBL. 4 and 5. Included with the available tools is Camshaft Bearing Remover and Installer Set BT-6409.378 . it is important that whenever a camshaft is installed it must first be coated liberally with GM Concentrate. IN. air conditioning condenser and front end sheet metal as necessary.472 . number 5 must be installed first.29619 .29600 .362 1.26880 425 CU. 5. then number 2.

Remove BT-6409-5 Installer and install BT-6409-4. use Puller BT-6409-8 as shown in Fig. Place Pilot BT-6409-6 on Driver BT-6409-7 and i n s t a l l No. 1. To remove No. 6B-165 i n s t a l l i n g Rear Cam Bearing . Install No. To replace bearings with engine in car. 4 bearing on installer 1. Mark top of bearing. 3. proceed as follows: Removal (Camshaft Removed) NOTE: To aid in aligning bearings with oil passages. 2 bearing. using BT-6409-3 and BT-6409-4 removers. 4. Remove No. Installation Fig. When installing the bearings the mark will act as a guide. 6B-165) 2. F i g . 6B-164 Removing Rear Cam Beari ng This set can be used to remove cam bearings with the engine either in or out of the car. 3 and No. NOTE: Each cam bearing is a different diameter and the correct sequence must be used both for removal and installation. 5 bearing on BT-6409-5 and drive bearing in until the last white line on the driver is flush with the front face of the pilot.All Series V-8 Engine 6B-31 2. 5 bearing with engine in chassis. Place new No. 6B-166. (Fig. 2 Cam Bearing Tool BT-6409-2 on driver and drive out No. place each bearing in the front bore with tapered edge toward block and align the oil hole in the bearing with the center of the oil slot in the bore. 4 bearings in the same manner. 3. 6B-164. Use BT-6409-9 to check oil hole opening as shown in Fig. 1 Cam Bearing Remover and Installer BT-6409-1 on Handle J-8092 (existing tool) and drive out front cam bearing. Place No.

6B-167 Installing No. In. 6 B . 6B-169 Installing Rear Main O i l Seal Upper Half 330 Cu. 2. 6B-166) Camshaft and Oil Galley Plugs (Fig. 6B-167) 6. .6B-32 V-8 Engine All Series Fig. The left hand r e a r oil galley plug is not shown. J Cam Bearing Installing Rear Main O i l Seal Upper Half 400 and 425 Cu. Wire must enter hole or the bearing will not receive sufficient lubrication. 5. In. Drive bearing in until white line on Installer BT-6409-1 is flush with front face of block. (Fig. 3 and No. 4. 6B-166 Checking No. Fig. (Fig. Follow the same procedure to install No. Use BT-6409-9 to check all oil hole openings. 6B-168 Camshaft and O i l Gallery Plugs Fig.1 6 8 ) Fig. Install Tool BT-6409-1 on Handle J-8092 and place No. 6B-170 Fig. 5 O i l Hole and drive in until second to last white line on driver is flush with pilot. 1 bearing on installer.

All Series

V-8 Engine

6B-33

It is a threaded ; u S t forward of provided in the The cup plug threaded plug.

plug in the end of the left galley the distributor. A small hole is plug for distributor lubrication. shown provides access to the

6B-169 for 330 cubic inch engine or Fig. 6B-170 for 400 and 425 cubic inch engines) 4. After oil passages in crankshaft have been checked for being open and shaft is clean, place shaft in block. Lubricate thrust flanges of the center bearing with 1050169 Lubricant. Install caps with lower half of bearing lubricated with SAE 10W30 oil. Lubricate cap bolts with Part No. 1050125 and install, but do not tighten. 5. With a block of wood (Fig. 6B-171) bump shaft in each direction to align thrust flanges of center main bearing. 6. Torque Nos. 1, 2, 3 and 4 main bearing cap bolts to 80 ft. lbs. and No. 5 bolt to 120 ft. lbs. (330 cu. in. engine). Torque Nos. 1 through 5 to 120 ft. lbs. (400 and 425 cu. in. engines). 7. Reassemble engine and install in chassis.

The front oil galley plugs (not shown) are threaded. The plug on the right side has a small hole which provides lubrication for the timing chain and gears.

CRANKSHAFT
Removal

It is recommended that the crankshaft be r e placed with the engine out of the chassis. In order to remove the crankshaft, the oil pan, front cover, connecting rods, transmission and flywheel must be removed from the engine.
Installation

MAIN BEARINGS Main bearing clearance must not exceed .0035" on all bearings. The .0035" clearance is permissible only if the engine is disassembled for other than a bearing noise condition. If bearings are noisy or if a visual inspection indicates defective bearings, new bearings must be installed within the specifications outlined under MAIN BEARINGS - REPLACE. Bearings which fall within the .0035" specification should not be rejected if the bearings show a normal wear pattern or slight radial grooves, unless it has been established to be defective.
Checking Bearing Clearances

1. Measure the crankshaft journals with a micrometer to determine the correct size rod and main bearings to be used. NOTE: Whenever a new or reconditioned crankshaft is installed, new connecting rod bearings and main b e a r i n g s should be installed. 2. Position upper half of main bearings in block and lubricate with SAE 10W30 oil. 3. Install a new r e a r main bearing seal. (Fig.

1. Remove bearing cap and wipe oil from crank-

Fig. 6B-171

Aligning Center Main Bearing Flanges

Fig. 6B-172

Checking O i l Clearance

6B-34

V-8 Engine

All Series

attempted. NOTE: The upper and lower shells must be installed in pairs. Sizes of the bearings are i0> cated on the tang. (Fig. 6B-173) It is possible to have more than one bearing size in the same engine. To install main bearing follows: shells, proceed as

1. Remove bearing cap and remove lower shell. 2. Insert a flattened cotter pin or roll out pin in the oil passage hole in the crankshaft, then rotate the crankshaft in the direction opposite to cranking rotation. The pin will contact the upper shell and roll it out. 3. The main bearing journals should be checked for roughness and wear. Slight roughness may be removed with a fine grit polishing cloth saturated with SAE 10W30 oil. Burrs may be removed with a fine oil stone. If the journals are scored or ridged, the crankshaft must be replaced. NOTE: The journals can be measured for out-of-round with the crankshaft installed by using a crankshaft caliper and inside micrometer or a main bearing micrometer. The upper bearing shell must be removed when measuring the crankshaft journals. Maximum out-of-round of the crankshaft journals must not exceed .0015". 4. Clean crankshaft journals and bearing caps thoroughly b e f o r e installing new m a i n bearings. 5. Apply Special Lubricant, Part No. 1050169, to the thrust flanges of bearing shells on No. 3 bearing. 6. Place new upper shell on crankshaft journal with locating tang in correct position and rotate shaft to turn it into place using cotter pin or roll out pin as during removal. 7. Place new bearing shell in bearing cap. 8. No. 5 bearing - install new asbestos oil seal in the rear main bearing cap. (REAR MAIN BEARING OIL SEAL) (Fig. 6B-174 for 330 cubic inch engine or Fig. 6B-175 for 400 and 425 cubic inch engines) 9. Install bearing caps, lubricate bolt threads with Part No. 1050125 Lubricant and install. Torque Nos. 1 through 4 to 80 ft. lbs. and No. 5 to 120 ft. lbs. (330 cu. in. engine) Torque Nos. 1 through 5 to 120 ft. lbs. (400

Fig. 6B-173

Main Bearing Identification

shaft journal and outer and inner surfaces of bearing shell. 2. Place a piece of plastigauge in the center of bearing. 3. Use a floor jack or other means to hold crankshaft against upper bearing shell. This is necessary to obtain accurate clearance readings when using plastigauge. 4. Reinstall bearing cap and bearing. Place Part No. 1050125 Lubricant on cap bolts and install. Torque Nos. 1, 2, 3 and 4 bolts to 80 ft. lbs. and No. 5 bolt to 120 ft. lbs. (330 cu. in. engine). Torque Nos. 1 through 5 to 120 ft. lbs. (400 and 425 cu. in. engines). 5. Remove bearing cap and determine bearing clearance by comparing the width of the flattened plastigauge at its widest point with graduation on the plastigauge container. The number within the graduation on the envelope indicates the clearance in thousandths of an inch. (Fig. 6B-172) If this clearance is greater than .0035", REPLACE BOTH BEARING SHELLS AS A SET. Recheck clearance after replacing shells. (Refer to MAIN BEARINGS - REPLACE). NOTE: Main bearing end thrust clearance should be .004" to .008" as checked with a dial indicator.
M a i n Bearings—Replace

Main bearing clearances not within specifications (.0005" to .0021") must be corrected by the use of selective upper and lower shells. UNDER NO CIRCUMSTANCES should the use of shims behind the shells, to compensate for wear, be

All Series

V-8 Engine

6B-35

correcting engine r e a r main bearing upper seal leaks without the necessity of removing the crankshaft. The procedure for seal leak correction is listed below. 1. Drain oil and remove oil pan and rear main bearing cap. 2. Insert Packing Tool BT-6433 or BT-6434 against one end of seal in cylinder block and drive the old seal gently into the groove until it is packed tight. This varies from 1/4" to 3/4" depending on the amount of pack r e quired. (Fig. 6B-176) 3. Repeat this on the other end of the seal in the cylinder block. 4. Measure the amount the seal was driven up on one side; add 1/16", then cut this length from the old seal removed from the main bearing cap with a single edge razor blade. Measure the amount the seal was driven up on other side. Add 1/16" and cut another length from old seal. Use main bearing cap as a holding fixture when cutting seal as shown in Fig. 6B-177. 5. Place a drop of 1050026 Sealer on each end of seal. 6. Work these two pieces of seal into the cylinder block (one piece on each side) with two small screwdrivers. Using Packing Tool, pack these short pieces up into the block. Use Seal Trimming Tool BT-6436 to trim seal flush with block as shown in Fig. 6B-178. NOTE; Place a piece of shim stock between seal and crankshaft to protect bearing surface before trimming. 7. Form a new rope seal in the rear main bearing cap as outlined. 8. Assemble the cap to the block and torque to specifications.

Fig. 6B-174

installing Rear Main O i l Seal Lower Half - 330 Cu. In.

Fig. 6B-175

Installing Rear Main O i l Seal Lower Half400 and 425 Cu. In.

and 425 cu. in. engines)

REAR M A I N B E A R I N G UPPER O I L SEAL

Repair

Tools have been released to provide a means of

Fig. 6B-176

Packing O i l Seal

Clean bearing cap and seal grooves and inspect for cracks. 2. Remove the r e a r main bearing cap. 2. packing by hand. 6B-179 Rear M a i n Seal Repair Tools . 3. (Fig. 6B-177 C u t t i n g O f f Lower Seal Ends REAR M A I N LOWER OIL SEAL F i g . 6B-178 C u t t i n g O f f Upper Seal Ends Removal 1. Using seal installer. main bearing insert and old 1. hammer seal into groove. Remove oil pan. Fig. Install seal into bearing cap. Installation 4. 6B-174 for 330 cubic inch engine or Fig.6B-36 V-8 Engine All Series Fig. Remove r e a r seals.

in. and No. 5. 8. slide the tool away from seal. 7. lbs. Install bearing caps. 1 through 4 to 80 ft. 5 to 120 ft. engine). Install pan with new gaskets.1 8 3 ) 6. Torque Nos. pack seal end fibers towards center. All old lubricant in the reservoir behind the bearing should be removed. cut seal flush with mating surface. Rotate seal installer when cutting seal to avoid damage to tool. lubricate bolt with Part No. the seal must be driven further into the seal groove. If tool butts against the seal. 6B-181). lbs. 6B-180 Engine Layout . (400 and 425 cu. When removing the pilot bearing. engines). Install the new bearing. lbs. 1 through 5 to 120 ft. 1050125 Lubricant and Torque Nos. remove with Pilot Bearing Puller BT-6619. 6B-182) STAKE BEARING (Fig. Clean bearing insert and install in bearing cap. PILOT BEARING (Manual Transmissioi On manual transmission equipped c a r s a pilot bearing is located in a bore in the rear end of the crankshaft. With tool slightly rotated. 3. the seal is fully seated. using Tool BT-6618 (Fig. in. If undercut area of tool slides over the seal. away from edges. Clean crankshaft contact. 4. (Fig. FLYWHEEL One bolt hole in the flywheel is offset and it Fig. 6 B . bearing journal and seal threads install. Rotate tool before cutting off excess seal packing. (330 cu. With screwdriver. Install lower flywheel cover. slide tool against the seal. With tool fully seated in the bearing cap.6B-175 for 400 and 425 cubic inch engines) NOTE: To check if seal is fully seated in the bearing cap.

6B-183 Staking Pilot Bearing Fig. Drill two 3/16" holes in the gear and then split with a sharp chisel.BT-6501 . 6B-182 Installing Pilot Bearing Fig. 6B-181 Removing Pilot Bearing will attach to the crankshaft in only one position. FLYWHEEL R I N G GEAR The flywheel ring gear may be replaced if damaged.6B-38 V-8 Engine All Series Fig. Heat the new gear with a torch and place in Fig. 6B-184 Engine Support Tool .

FUEL PUMPS (Fig. The pumps are serviced only as an assembly and can be identified by parts numbers stamped on the pump mounting base. Three on V-8 and two on the L-6. Operating pressures for the L-6 engine are 4 to 5 psi without K-19 and 5-1/2 to 7 psi with K-19. Fig. it will become tight on the flywheel. 6B-185 Fuel Pump Identification . As the gear cools.1 8 5 ) Five different fuel pumps will be used in 1966.All Series V-8 Engine 6B-39 sition o n t n e flywheel. All pumps have a sheet metal cover permanently sealed to the pump housing and cannot be disassembled for service. 6 B . Pump operating pressures for all V-8 fuel pumps will be 7-3/4 to 9 psi.

VALVE GUIDE REAMER CAMSHAFT GEAR REMOVAL PLATE CAMSHAFT GEAR INSTALLER CAMSHAFT GEAR REMOVER VALVE ROCKER ARM STUD INSTALLER ROCKER ARM STUD REAMER .S. VALVE GUIDE REAMER J-5830-2 .015" O.S.003" O. MANIFOLD HEAT RISER BUSHING SET CRANKSHAFT PULLEY REMOVER PISTON PIN TOOLS PISTON PIN ADAPTER (L-6) VALVE SPRING COMPRESSOR VALVE SPRING COMPRESSOR ADAPTER BT-6616 J-7583-3 BT-6610 BT-6601 J-5154 J-5830 CRANKSHAFT PULLEY REMOVER PILOT SCREW (USED WITH J-8614) CRANKSHAFT PULLEY AND GEAR REMOVER PLATE SCREW CRANKSHAFT TIMING GEAR AND FRONT OIL SEAL INSTALLER (L-6) J-5830-1 .S.6B-40 V-8 Engine All Series * BT-6606 BT-6225 BT-6618 BT-6310 S-141 BT-6613 BT-6513 BT-6619 BT-6611 BT-6607 J-8614 BT-6408 BT-6614 BT-6413 BT-6612 ENGINE LIFT CHAIN COOL ING SYSTEM TESTER CLUTCH PILOT BEARING INSTALLER CARBURETOR FLOAT GAUGE CARBURETOR FUEL INLET NUT WRENCH ADAPTER FOR NEEDLE AND SEAT TESTER CARBURETOR NEEDLE AND SEAT CHECKER CLUTCH PILOT BEARING REMOVER CRANKSHAFT PULLEY INSTALLER (V-8) EXH.S.003" O. DISTRIBUTOR BUSHING INSTALLER DISTRIBUTOR BUSHING REMOVER FRONT COVER CENTERING GAUGE (L-6) CLUTCH PILOT BUSHING REMOVER (L-6) FRONT SEAL REMOVER PILOT FOR TOOL BT-6406 CAMSHAFT BEAR I NG SET J-22227 J-21795 J-8810 J-8880 J-5715 J-6036 J-9535 J-9534 J-21742 J-1448 BT-6406 J-9395 BT-6609 Fig.030" O. VALVE GUIDE REAMER J-5830-3 . ROCKER ARM STUD REAMER . 6B-186 Tools .013" O.S.

209" 004"-.25:1 1-8-4-3-6-5-7-2 2. of Oil Rings (per piston) Gap Clearance. 2 Bbl.) CRANKSHAFT Diameter-Main Bearing Journal (all) Width-Main Bearing Journal (with fillets) No. of Cylinders Bore and Stroke (all) Piston Displacement (all) Compression Ratio Firing Order Main Bearing Bore (I.Oil Ring 90° V-Type 8 3.9795" 0015"-.688" 2.201" 1. In.0030" 002"-. 3 No. 3 No.055" 0001"-.9375" 3.2495"-2.0016" Tight 2 0780"-.687"-2.877"-1. 5 CONNECTING RODS Length-Center to Center Diameter-Connecting Rod Bore Diameter-Pin Bore Bearing Clearance . 5 Diameter-Connecting Rod Bearing Journal Width-Connecting Rod Bearing (with fillets) Length-Overall Crankshaft Diameter .624" 5. 0000"-.020" 0018"-. 10. 1.156"-1.116"-3.D.3850" 330 Cu.872" 2.All Series V-8 Engine 6B-41 3 3 0 CUBIC INCH ENGINE SPECIFICATIONS CYLINDER BLOCK Engine Type No.880" 26. 4 Bbl. 2 & 4 No. .0038" 1 015"-.Oil Holes in Crankshaft Clearance .Crankshaft End Thrust MAIN BEARINGS Oil Clearance-Crankshaft Vertical (all) Width-Bearing Shell No.185" 1. and 4 No.00125" 20. 2.615" 00075"-.12388" 1.008" 0015"-.0033" 0018"-.0775" 010"-.0031" 970"-. of Compression Rings (per piston) Width of Compression Rings (top & bottom) Gap Clearance Compression Rings Clearance in Groove Compression Rings .0:1.Crankshaft End PISTON Diameter Nominal Outside Length Overall Top of Piston Pin to Center Clearance at Thrust Surface (selective) Weight Less Pin & Rings (all) Skirt Taper Ring Width (2 compression) (1 oil) PISTON PINS Diameter Length Overall Pin to Piston Clearance Pin to Rod Clearance PISTON RINGS No.9791"-. 1 No.9385" x 3.013" 3.Upper Lower No.670 oz.1248"-2.Crankshaft (vertical) Side Clearance .0051" .4985" 1. Oil Ring Clearance in Groove .002" 2.0005" Loose 0008"-.980" 1.4995"-2.136" 0003"-.9803" 3.195" 1. 9.2500" .193"-1.470" 201"-. .620" 1.199"-1.166" 1.0010" Larger at Bottom 0803" 1886" 9807"-.998"-6.

1 No.0015"-. 3.Valve Seat Overall Length (all) Clearance in Guide Lash VALVE .9965" 1.270" VALVE LIFTERS Diameter .0373"-2.886"-1.Stem Angle .) CAMSHAFT Bearing Journal Diameters No. 2 No.750" 48 500" .INTAKE Diameter . 5 Journal Clearance in Bearing (all) End Thrust VALVE .400" 1. 4 No.041" 76-84 Lbs.Body Length .400" 500" 36 471"-.993" 500" 18 740"-. of Teeth TIMING CHAIN Width No.Head Diameter .3432" 45° 037"-. 180-194 Lbs.0165" 1.670" Load @ 1.075" 4. 3 No.Valve Seat Overall Length (all) Clearance in Guide Lash VALVE GUIDES Inside Diameter (intake & exhaust) VALVE SPRINGS Length Diameter . 1 No.0020" 410"-. 5 Width (including chamfers) No.728" .461" 410"-.077" 1. of Links Pitch 2.870" 3425"-.0173"-2.065"-1.Stem Angle .96" 192" 1.8427" 2.557" 3420"-.0027" Hydraulic 1. 8422"-.Valve Seat Width .567"-1.Head Diameter .Overall Clearance in Boss (selective) CAMSHAFT SPROCKET Width of Sprocket Pitch No.0050" Oil"-.6B-42 V-8 Engine All Series 3 3 0 CUBIC INCH ENGINE SPECIFICATIONS (Cont'd.0032" Hydraulic 3442"-.9565" 810" 768" 775" 0012 M -.9973"-1.Valve Seat Width .740" 0010"-.3452" 1.9573"-1.000" 0005"-.0365" 2.3427" 45° 037"-.9765" 1.075" 4.Wire Inside Diameter Load @ 1.EXHAUST Diameter . of Teeth Overall Width of Gear CRANKSHAFT SPROCKET Width of Sprocket Overall Width of Gear Pitch No.00"-. 2. and 4 No.9773"-1.

Oil Holes in Crankshaft Clearance .620" 1. .6250" 9791"-.055" 0021"-.195" 1. 1 No.Crankshaft End Thrust MAIN BEARINGS Oil Clearance-Crankshaft Vertical 1.199"-1.980" 1.0033" .6243"-2.9807" 3.116"-3.624" 6. 10. In.189" 3.25:1 1-8-4-3-6-5-7-2 3.0016" Tight 2 0780"-.0003"-2. of Compression Rings (per piston) Width of Compression Rings (top & bottom) Gap Clearance Compression Rings Clearance in Groove Compression Rings .880" 26. 2 & 4 No.188"-3. of Oil Rings (per piston) Gap Clearance.0000"-.Crankshaft (vertical) Side Clearance .193"-1.126" x 3. 5 Diameter-Connecting Rod Bearing Journal Width-Connecting Rod Bearing (with fillets) Length-Overall Crankshaft Diameter .4988" 1.975" 400 Cu. .872" 2. 3 No.0005" Loose 0008"-.9795" 0008"-.00125" 23.166" 1.156"-1.All Series V-8 Engine 6B-43 400 CUBIC INCH ENGINE SPECIFICATIONS CYLINDER BLOCK Engine Type No.023" 0018"-.D.877"-1.Oil Ring 90° V-Type 8 4.185" 1. of Cylinders Bore and Stroke (all) Piston Displacement (all) Compression Ratio Firing Order Main Bearing Bore (I. 3 No. 2.470" 201 "-.0010" Larger at Bottom 0803" 1886" 9803"-.996"-7. 3 & 4 5 Width-Bearing Shell No.008" 0015"-. Oil Ring Clearance in Groove .460 Oz.) CRANKSHAFT Diameter-Main Bearing Journal (all) Width-Main Bearing Journal (with fillets) No. and 4 No.0081" .5003"-2.0038" 1 015"-. 1. 0031" 0020" -.Crankshaft End PISTON Diameter Nominal Outside Length Overall Top of Piston Pin to Center Clearance at Thrust Surface (selective) Weight Less Pin & Rings (all) Skirt Taper Ring Width (2 compression) (1 oil) PISTON PINS Diameter Length Overall Pin to Piston Clearance Pin to Rod Clearance PISTON RINGS No.013" 4" 3.615" 00075"-. 2.0034" 970"-. 5 CONNECTING RODS Length-Center to Center Diameter-Connecting Rod Bore Diameter-Pin Bore Bearing Clearance .136" 0003"-.9993" 1.0018"-.0775" 013"-.209" 004"-.Upper Lower No.201" 1.0018" 002"-.000" 2.

3452" 1.670" Load @ 1.Stem Angle .077" 2.0373"-2.9565" 810" 768" 775" 0012"-. 180-194 Lbs.Valve Seat Overall Length Starfire Clearance in Guide Lash VALVE .844"-Linkbelt 48 500" .Head Diameter .9965" 1. of Links Pitch 2.125" 0005"-.270" VALVE LIFTERS Diameter .9215" 2. 1 No.593" 001" to .96" 192" 1. 9210"~.9973"-1. 3 No.0365" 2.0165" 1.9573"-1. 5 Width (including chamfers) No.461" 530"-. 5 Journal Clearance in Bearing (all) End Thrust VALVE . 2.065"-1.041" 76-84 Lbs. and 4 No.3432" 30° 030"-.) CAMSHAFT Bearing Journal Diameters No.587" 001" to . 4 No.3427" 45° 037"-.003" Hydraulic 3442"-.9773"-1.062"-2.993" 500" 18 875"-Morse. 3.052" 3425"-.Head Diameter .6B-44 V-8 Engine All Series 4 0 0 CUBIC INCH ENGINE SPECIFICATIONS (Cont'd.Overall Clearance in Boss (selective) CAMSHAFT SPROCKET Width of Sprocket Pitch No.003" Hydraulic 1.619" 3420"-.075" 4.Valve Seat Overall Length Clearance in Guide Lash VALVE GUIDES Inside Diameter (intake & exhaust) VALVE SPRINGS Length Diameter .063" 4. 1 No.0020" 529"-.0050" 011"-.520" 1.1073"-2. . 2 No.INTAKE Diameter .Stem Angle .Valve Seat Width .629"-1.521" 500" 36 471"-.001"-.Valve Seat Width . of Teeth TIMING CHAIN Width No.Body Length .EXHAUST Diameter .Wire Inside Diameter Load @ 1. of Teeth Overall Width of Gear Hub CRANKSHAFT SPROCKET Width of Sprocket Overall Width of Gear Pitch No.9765" 1.

156"-1. (1 oil) PISTON PINS Diameter Length Overall Pin to Piston Clearance Pin to Rod Clearance PISTON RINGS No. 2 & 4 No.872" 2.877"-1.Upper Lower No. 5 CONNECTING RODS Length-Center to Center Diameter-Connecting Rod Bore Diameter-Pin Bore Bearing Clearance .460 Oz.189" 3.Oil Ring 90° V-Type 8 4.0034" 970"-.All Series V-8 Engine 6B-45 4 2 5 CUBIC INCH 54 THROUGH 86 SERIES ENGINE SPECIFICATIONS CYLINDER BLOCK Engine Type No.9993" 1.055" 0021"-.0033" 0018"-.470" 201 "-. In.0005" Loose 0008"-.5003"-2.0031" 0020"-.0038" 1 015"-.0003"-2.000" 2.9795" 0008"-. of Cylinders Bore and Stroke (all) Piston Displacement (all) Compression Ratio Firing Order Main Bearing Bore (I. See Engine Ident. 0000"-. Oil Ring Clearance in Groove . 2. 3 No.126" x 3. of Compression Rings (per piston) Width of Compression Rings (top & bottom) Gap Clearance Compression Rings Clearance in Groove Compression Rings .0081" . of Oil Rings (per piston) Gap Clearance.013" 4. Chart Section "O and OE" 1-8-4-3-6-5-7-2 3.00125" 23.199"-1.Crankshaft End PISTON Diameter Nominal Outside Length Overall Top of Piston Pin to Center Clearance at Thrust Surface (selective) Weight Less Pin & Rings (all) Skirt Taper Ring Width (2 compression) .0010" Larger at Bottom 0803" 1886" 9803"-.996"-7. 2.188"-3.880" 26.0016" Tight 2 0780"-.D. 1 No. 3 & 4 5 Width-Bearing Shell No.136" 0003"-.9807" 3.615" 00075"-.116"-3.201" 1.0018" 002"-. and 4 No.6243"-2.195" 1. 5 Diameter-Connecting Rod Bearing Journal Width-Connecting Rod Bearing (with fillets) Length-Overall Crankshaft Diameter .Crankshaft (vertical) Side Clearance . .209" 004"-.Crankshaft End Thrust MAIN BEARINGS Oil Clearance-Crankshaft Vertical 1.6250" 9791"-.008" 0015"-.0775" 013"-.166" 1. 3 No.023" 0018"-.980" 1.620" 1. 1.975" 425 Cu.4988" 1.125" 3.Oil Holes in Crankshaft Clearance .185" 1. .624" 6.193"-1.) CRANKSHAFT Diameter-Main Bearing Journal (all) Width-Main Bearing Journal (with fillets) No.

2 No.075" 4. of Teeth Overall Width of Gear Hub CRANKSHAFT SPROCKET Width of Sprocket Overall Width of Gear Pitch No.Valve Seat Overall Length Starfire Overall Length (except Starfire) Clearance in Guide Lash VALVE .001"-.3425"-.065"-1.125" 0005"-.587" 4.96" 192" 1. 9210"-.3432" 30° 030 n -.0050" 011"-. of Teeth TIMING CHAIN Width No.9215" 2.EXHAUST Diameter .Head Diameter .563" 001"-.9565" 810" 768" 775" 0012"-. and 4 No.0020" 529"-.0165" 1.1073"-2. 2.Valve Seat Width .077" 2.521" 500" 36 471"-.9573"-1.INTAKE Diameter .461" 530"-.9773"-1.003" Hydraulic 1.593" 4.003" Hydraulic 3442"-. 3.629"-1.9973"-1.9765" 1.Valve Seat Width .Wire Inside Diameter Load @ 1.) CAMSHAFT Bearing Journal Diameters No.270" VALVE LIFTERS Diameter .670" Load @ 1. 1 No.619" 3420"-.3452" 1.0365" 2. of Links Pitch 2.6B-46 V-8 Engine All Series 425 CUBIC INCH 54 THROUGH 86 SERIES ENGINE SPECIFICATIONS (Cont'd.Stem Angle .000"-1.Head Diameter .9965" 1.557" 001"-.063" 4. 4 No.0373"-2.Overall Clearance in Boss (selective) CAMSHAFT SPROCKET Width of Sprocket Pitch No.041" 76-84 Lbs.Stem Angle . 1 No. 844"-Linkbelt 48 500" . 180-194 Lbs. 5 Width (including chamfers) No.993" 500" 18 875"-Morse. 5 Journal Clearance in Bearing (all) End Thrust VALVE .3427" 45° 037"-.990" .Valve Seat Overall Length Starfire Overall Length (except Starfire) Clearance in Guide Lash VALVE GUIDES Inside Diameter (intake & exhaust) VALVE SPRINGS Length Diameter .Body Length .520" 1. 3 No.

Lbs.8 ENGINES) FLYWHEEL No. 5 Qts.0050" 0025"-.All Series V-8 Engine 6B-47 ENGINE SPECIFICATIONS (ALL V . engine) Crankshaft Bearing Cap No. in. of Teeth on Starter Gear No. 0025"-. Ft. in. of Teeth on Starter Pinion LUBRICATION SYSTEM Crankcase Capacity Drain and Refill Drain & Refill with Filter Change Oil Pump Clearance P r e s s u r e Relief Valve in Bore End Clearance . 1. and 425 cu. engines) Crankshaft Bearing Cap Bolts Nos. . engine) •Cylinder Head to Block Connecting Rod Nuts Oil Pump to Bearing Cap Bolts Oil Pump Cover to Pump Bolts Rocker Arm Studs to Head Rocker Arm Nuts to Studs Valve Cover Bolts Oil Pan Bolts 5/16" Oil Pan Bolts 1/4" Oil Pan Drain Plug Crankshaft Balancer or Hub to Crankshaft Bolt Oil Filter Element to Base Oil Filter Assembly to Cylinder Block Bolts Front Cover to Cylinder Block Bolts 3/8" Front Cover to Cylinder Block Bolts 5/16" Fan Driven Pulley to Hub Bolts Fan Driving Pulley to Hub or Balancer Bolts Water Pump to Front Cover Bolts Water Outlet to Manifold Bolts *Intake Manifold to Cylinder Head Bolts Intake Manifold Baffle to Cylinder Block Bolts Exhaust Manifold to Cylinder Head Bolts Carburetor to Intake Manifold Bolts Tube and Plate to Intake Manifold Bolts Air Cleaner to Carburetor Stud Motor Mount to Cylinder Block Bolts Starter to Cylinder Block Bolts Starter Brace to Cylinder Block Bolt Starter Brace to Starter Bolt Distributor Clamp to Cylinder Block Bolt Spark Plugs Coil to Intake Manifold Bolt •Clean and dip entire bolt in engine oil before tightening to avoid an erroneous torque reading. Application FUEL PUMP Fuel Pump to Block Bolt and Nut Fuel Pump Eccentric to Camshaft EXHAUST SYSTEM 25 65 15-20 120 80 120 80 42 35 8 35 25 7 15 8 50 50 20 35 35 25 20 20 13 20 35 8 25 15 15 5 50 35 25 15 14 35 15 ENGINE Crankshaft Bearing Cap Bolts (400 cu. 5 (330 cu. in. in. Checking of torque during inspection may be 10% below specification.0065" TORQUE SPECIFICATIONS NOTE: Specified torque is for installation of parts only. 3 & 4 (330 cu. 2.Gear 166 9 4 Qts.

Power Steering and Compressor Mounting Brackets.6B-48 V-8 Engine All Series For Torque Requirements on Generator. Refer to Table Below: Bolt Size 5/16" 3/8" 7/16" Torque 25 35 50 .

016" (used points). File center electrode flat. 4. Refer to Idle Speed Chart in this section for specifications. Adjust distributor contact point gap to . 3. Apply a film of cam and ball bearing lubricant or equivalent to the breaker cam. Remove scale from points with a fine cut contact point file. slow and fast idle speed. . check for excessive burning or pitting.000 miles: Service the spark plugs and ignition points. 2. 6C-1 Filing Center Electrode 1. check the timing. Install plugs using new gaskets and torque 35 ft. Inspect points.V-8 IGNITION SYSTEM DIAGNOSIS TUNE-UP CHART DISTRIBUTOR TEST SPECS 6C-4 6C-4 6C-5 6C-6 6C-9 6C-9 ENGINE TUNE-UP To maintain the most satisfactory engine performance. (Fig. Clean all serviceable plugs with an abrasive type cleaner. using a feeler gauge or dial indicator.030" using a round feeler gauge. Calibrate dwell meter to set line and connect one lead of dwell meter to the primary . it is recommended that the following items be performed every 12.8 ENGINE) Fig. Remove foreign material from around the 1. 6C-1) Do not file center electrode on new plugs.All Series Engine Tune-Up 6C-1 ENGINE TUNE-UP (ALL SERIES) CONTENTS OF SECTION 6C Subject Page Subject Page ENGINE TUNE-UP 6C-1 SPARK PLUGS 6C-1 DISTRIBUTOR CONTACT POINTS . Rotate engine until breaker arm rubbing block is on high point of lobe. 6C-2) DWELL ANGLE ( V . 2. Adjust spark plug gap to . Clean exterior of plugs and inspect for cracked insulators or excessively burned electrodes.L-6 6C-3 CYLINDER HEAD TORQUE AND VALVE ADJUSTMENT COMPRESSION TEST ON-CAR ADJUSTMENTS .019" (new points) or . Cars equipped with K-19 Air Injection Reactor System require no special maintenance or procedure recommendations other than an annual tune-up and air pump belt inspection and adjustment. 5. 2. 3.6C-1 DWELL ANGLE 6C-1 IGNITION TIMING 6C-2 SLOW IDLE ADJUSTMENT 6C-2 ON-CAR ADJUSTMENTS . (Fig. DISTRIBUTOR CONTACT POINTS 1. . lbs. Contact Point Adjustment (L-6 Engine) 1. . Replace if necessary. idle mixture. SPARK PLUGS spark plug holes and remove the spark plugs. All other specifications are the same as for c a r s without K-19. Do not attempt to remove all roughness.

6C-3) Adjust dwell angle to 30°. 2. SLOW IDLE ADJUSTMENT The ignition timing marks are located on the engine front cover. Fig. Tighten the distributor clamp bolt and recheck timing to make sure distributor was not moved during tightening of bolt. In areas that have an extra high octane. 6C-3 Fig. With engine running at idle speed. NOTE: The L-6 timing pointer is marked in 2° increments. (Fig. 4. the cause is low octane fuel or With the engine at normal operating temperature and air cleaner removed. adjust slow idle as outlined in chart. 6C-4) To adjust ignition timing.6C-2 Engine Tune-Up All Series Fig. Adjust engine speed to 850 rpm. insert Dwell Adjusting Tool J-6296 or BT-1501 through distributor window into the head of the adjusting screw. (Fig. Remove tape and connect distributor vacuum advance line. 6C-4 Timing Marks . IGNITION T I M I N G excessive carbon build-up in the combustion chamber. With the use of a timing line set timing according to chart. (500 rpm on L-6) 3. NOTE: If a tuned engine detonates with this setting. If these factors are not corrected. To adjust the ignition timing loosen the distributor clamp bolt and rotate the distributor. Disconnect distributor vacuum line at carburetor and cover fitting with tape. the timing should be retarded 2-1/2° from the specified settings. The " O " marking is TDC and all BTDC settings are on the " A " (advance) side of " O " . 6C-2 Contact Point Adjustment (L-6 Engine) Adjusting Dwell Angle (V-8 Engine) distributor lead terminal (negative (-) terminal of coil) and the other lead to ground. A saw slot on the balancer indicates engine top dead center. proceed as follows: 1. the timing may be advanced beyond the specified setting providing spark knock is not encountered. 5.

All Series Engine Tune-Up 6C-3 Fig. 6C-5 On-Car Adjustments (L-6 Engine) .

After the engine has been normalized. CYLINDER HEAD TORQUE A N D VALVE ADJUSTMENT (L-6 ONLY) PROCEDURE 1. 4. . cylinder head and cylinder block are relative to this oil temperature. Turn nut down 1/4 additional turn and pause 10 seconds until engine runs smoothly. do these parts stop expanding and valve clearance changes cease to take place. turn in or out each idle adjusting screw until the smoothest possible idle is obtained. Adjusting the valves during or before this warm-up period will produce clearances which will be far from correct after the engine reaches normal operating temperature. it does not change the rate at which the oil temperature increases or the engine parts become normalized. Therefore. 3. The expansion or contraction of the valves. Tool BT-1501 can be used to turn idle mixture adjusting screws. COMPRESSION TEST Retorquing the cylinder head bolts is not necessary unless a gasket has been replaced. between the inlet valve head and top of piston. With the engine running at idle. NOTE: It may be necessary to readjust idle speed and mixture after air cleaner is installed on car. only after the oil temperature is stabilized. When setting idle speed and mixture on carburetors with an idle compensator (factory installed air conditioning only). When checking cylinder compression. With this system. The actual temperature of the oil is not as important as stabilizing the oil temperature. readjust to correct rpm. This is very important because during the warm-up period.6C-4 Engine Tune-Up All Series After the idle rpm is stabilized. This is the zero lash position. Before adjusting the valve stem to rocker arm clearance. it is extremely important that the engine be thoroughly warmed up to normalize the expansion of all parts. 6. The lowest reading cylinder should not be less than 80% of the highest. Repeat Steps 2. the starter must not be energized when the ignition switch is in the "off" position. 5.005" from a cold check through the normalizing range. at which time both vacuum and idle rpm will drop off slightly. Energizing the starter will cause damage to the ground contact in the ignition switch and to the ignition contact in the starter solenoid. NOTE: If equipped with G67. Noisy lifters should be replaced. using new gaskets. the ignition system primary is grounded in the ignition switch. back off valve rocker arm nut until the valve rocker arm starts to clatter. Tests have shown that valve clearances will vary as much as . all spark plugs removed. and no cylinder reading should be less than 100 pounds. and the battery at or near full charge. which might result in internal damage and/or bent push rods. To determine if the valves or pistons are at fault. or a leak is suspected. pausing 10 seconds each time. NOTE: The ignition resistor is by-passed during cranking through a contact in the starter instead of through a contact in the ignition switch. Turn rocker arm nut down slowly until the clatter just stops. NOTE: This 1 turn preload adjustment must be done slowly to allow the lifter to adjust itself to prevent the possibility of interference. This is normally accompanied by a higher manifold vacuum reading and/or an increase in idle rpm. If the idle speed increases when the air cleaner is installed. vacuum pump must not be operating. Then turn out each needle 1/4 turn. Covering the radiator will not materially hasten this normalizing process because even with the water temperature quickly raised. If idle speed decreases. the valve clearances will change considerably. In this position. the throttle and choke should be open. Valve lash must always be adjusted after the head has been torqued. remove rocker arm covers and gaskets. push rods. do not reduce idle speed setting since the idle compensator is open. Clean gasket surfaces on cylinder heads and rocker arm covers with degreaser then install rocker arm covers. a test should be made to determine the cylinder compression pressure. and torque bolts to specifications. 2. until nut has been turned down 1 full turn from the zero lash position. 3 and 4 to adjust the rest of the valves. consequently the engine should be run 15-20 minutes to properly normalize all parts. Gaskets adhearing to cylinder head and rocker arm cover may be sheared by bumping end of rocker arm cover rearward with palm of hand or a rubber mallet. make sure the idle compensator is closed by holding it down with a pencil or other suitable tool. Repeat additional 1/4 turns. NOTE: Do not pry rocker arm cover loose.

All Series Engine Tune-Up 6C-5 Fig. 6C-6 On-Car Adfusfmenfs (V-8 Engine) .

5. Vapor lock. Worn or seized piston rings. Fig. Spark plugs fouled. 11. Lack of fuel at carburetor. Weak or shorted coil or condenser. IGNITION SYSTEM DIAGNOSIS HIGH SPEED PERFORMANCE Fig. incorrect gap or heat range. Low fuel pump pressure. 8. Does not improve much with addition of oil. 18.Low on first stroke does not tend to build up on following strokes. Stuck heat r i s e r valve. low floats. 9. 13. 17. 7. 16. Distributor points or incorrect dwell and ignition timing. 12. Burned or sticky valves. Retarded valve timing. Foreign material or water in fuel. Restricted exhaust system. 6C-8 Throttle Linkage . 4. . I m p r o v e s considerably with addition of oil. 2. Restricted high speed jets.Compression low on first stroke tends to build up on following strokes but does not reach normal. weak or broken springs.L-<6 Engine . Excessive carbon in heads. Stuck power valve or piston. 14. Piston Rings 1. 19. High engine oil pump pressure. 3.6C-6 Engine Tune-Up All Series Valves . 15. Insufficient vacuum advance. 10. Plugged carburetor air cleaner. 6. 6C-7 Accelerator Pedal (L-6 Engine) Normal _ Compression builds up quickly and evenly to specified compression on each cylinder. Transmission slipping. Closed or partially closed choke. 20.

36 and 38 Series) .All Series Engine Tune-Up 6C-7 Fig. 6C-10 Throttle Linkage (34. 6C-9 Throttle Linkage (52 through 86 Series) Fig.

Stuck heat r i s e r valve. Vacuum leak. Lack of fuel at carburetor. 12. Spark plugs fouled. 18. Ignition switch problems. Low compression. Distributor points burned or misadjusted. Low engine vacuum. 10. Low compression. Closed or partially closed choke. 3. Remove spark plugs to look for water or gasoline in cylinders. 8. 6. 17. 11. HARD START HOT 1. IDLE—MISSES OR ROUGH 1. 12. Low battery. 6. 8. Loose coil or ignition wires. Lack of fuel at carburetor. Spark plugs fouled or cracked. Retarded or advanced valve timing. Choke stuck open. weak or broken springs. Distributor points burned or misadjusted. 14. Starter drawing excessive amperage. 9. Starter drawing excessive amperage. Incorrect dwell and ignition timing. 9. 6. Stuck power piston or wrong size in m e tering jets. 4. 1. 11. 4. 4. 16. 13. Foreign material or water in fuel system. Low battery. 3. 9. Brake drag. High fuel pump pressure. 14. Distributor points burned. 12. 14. . Stuck heat riser valve. Flooding condition. 7. Hydrostatic lockup. Flooding condition. High fuel pump pressure. Stuck heat riser valve. Spark plug or distributor wires loose or shorted. Shorted distributor condenser. Weak or shorted coil. 8. 8. Turn crank pulley with socket and ratchet. Battery cables loose or corroded. Loose coil or ignition wires. 1. 9. shows rich gas mixture. Battery cables loose or corroded. 5. Plugged positive crankcase ventilation system. 2. 5. Defective starter motor. Plugged carburetor air cleaner. 12. Low battery. Ignition switch problems. 5. HARD START COLD GAS MILEAGE 1. 2. ENGINE W O N ' T CRANK 7. 4. Vapor lock. 7. Seized engine. no spark at plugs. 6. Misadjusted transmission stator switch. Starter drawing excessive amperage. Incorrect axle ratio. 5. 7. Leaky head gaskets.6C-8 Engine Tune-Up All Series ENGINE WILL CRANK BUT W O N ' T START 1. 13. Worn cam lobe. Burned or sticky valves. 6. 3. Transmission slipping or high shifts. 11. 14. Weak or shorted coil. 2. Weak or shorted coil. Misadjusted or defective neutral safety switch. Discrepancy while flow meter testing and driver's habits. Low battery and loose or corroded cables. Low compression. 3. 2. 10. 5. 4. 3. Distributor points burned or misadjusted. 2. Low tire pressure. Plugged idle jets or improperly adjusted idle screws. 19. 4„ 5. 3. High or misaligned floats. Carburetor icing. 15. Weak or shorted coil. Closed choke. Wrong speedometer gear. 7. Plugged positive crankcase ventilation system. Black smoke at tail pipe. Carburetor dechoker misadjusted. Distributor points misadjusted or burned or shorted condenser. 11. 13. Carburetor or atmospheric vent closed. 15. 2. Spark plugs fouled. Spark plugs fouled. Plugged carburetor air cleaner. 10. 10. 6. 13. Incorrect air fuel ratio at 1500 rpm test.

Hg. 9° 15-1/2 to 19-1/2 In. .C. Hg.) 425 Cu. Start 8 to 10 In. Carb. 1111048 1116232 9° 15-1/2 to 19-1/2 In. In. Hg. * Refer to Engine Identification chart.C.C. Hg.030" Set Dwell 31°-34° 30° 30° 30° 30° 30° 30° 30° Breaker Gap .) Spark Plugs 46N 45S 44S 44S 44S 45S 44S 44S Plug Gap . .H. Start 6 to 8 In. In. Ratio DISTRIBUTOR Part No. . .5° (850 RPM) *For choke settings refer to Carb.(2 Bbl. Hg. Vacuum Unit No.L.(2 Bbl. Hg.5° (850 RPM) 7. Mechanical Advance Per Distributor RPM 0° 2-1/2° 6-1/2° 13° to to to to 500 2° 4-1/2° 600 8-1/2° 800 1400 15° RPM RPM RPM RPM (L-6) 250 All Start 1110351 1116235 10° *H. Carb. Hg.C. . Charts.H. . DISTRIBUTOR TEST SPECIFICATIONS ENGINE Cu. 2 Bbl.) 330 Cu. . . 1111151 1115361 9° 16-1/2 to 18-1/2 In.5° (850 RPM) 7.(4 Bbl. In.030" . Hg.(2 Bbl.) 425 Cu.030" .019" Set Choke * * * * * * * * 7. In. Hg.) 330 Cu.C. 400 425 Start 6 to 8 In. . . 14-1/2 In. In. .5° (850 RPM) 5° (850 RPM) 7. .030" . . In. Hg. H. **Comp.L. BASED ON DISTRIBUTOR RPM Vacuum Advance Per Inch Of Vacuum 5 to 7 In.L-6 (1 Bbl.H. . 400 RPM 0° to 2° 7-3/4° to 9-3/4° 1025 RPM 2000 RPM 14° to 16° 400 RPM 0° to 2° 7-1/2° to 9-1/2° 1000 RPM 2125 RPM 12° to 14° 0° to 2° 6° to 8° 10° to 12° 400 RPM 900 RPM 2000 RPM All Start 6 to 8 In. 425 600 RPM 0° to 2° 3-1/2° to 5-1/2° 900 RPM 2100 RPM 8° to 10° 0° to 2° 13° to 15° 400 RPM 2000 RPM 425 * Engine options L74 and L76 use the same distributor. Section 6M.) 425 Cu. Hg.C.030" .035" . In.) 330 Cu. In.C. Hg. In.C.030" .C.C.030" .(4 Bbl. 330 L.(4 Bbl.) 400 Cu. **Refer to Engine Identification Chart.5° (850 RPM) 7. 4 Bbl.All Series Engine Tune-Up 6C-9 ENGINE TUNE-UP CHART Set Timing (Vacuum Disconnected) 6° (500 RPM) **Engine Usage 250 Cu. Start 6 to 8 In.(2 Bbl.5° (850 RPM) 7.C. 1111089 1116232 9° 15-1/2 to 19-1/2 In. Spec.H. Adj. . 1111029 1116232 9° 15-1/2 to 19-1/2 In. 1111042 1116232 H. L.

6C-10 Engine Tune-Up All Series .

The inlet pipe cast in the pump cover feeds into the passage formed by the cover and the front face of the impeller. A nipple in the manifold allows connection of the heater hose. 6K-1 Pressure Radiator C a p The pressure type radiator filler cap contains a blow off or pressure valve and a vacuum or atmospheric valve. Next. allows recirculation of coolant through the engine to provide rapid warm-up.Engine Cooling 6K-1 ENGINE COOLING SYSTEM ALL ENGINES CONTENTS OF SECTION 6K Subject ENGINE COOLING SYSTEM COOLING SYSTEM .8 ENGINE (Fig. At the forward end of the cylinder heads the coolant flows into the intake manifold. After flowing the full length of the cylinder banks. 6K-1) The higher pressure raises the boiling point of the coolant and increases the cooling efficiency of the radiator. The vacuum valve is held against its seat by a light spring which permits opening of the valve to relieve vacuum created when the system cools off. When the thermostat opens. The coolant then flows rearward through the water jacket which surrounds each cylinder barrel and extends below the lower limit of piston ring travel. COOLING SYSTEM CIRCULATION V . through the radiator core and lower tank to the water pump inlet where the cycle is repeated. the coolant flows up through openings to the r e a r of the cylinder bank into the cylinder heads. The coolant flows forward in the cylinder heads to cool the combustion chamber areas. which is mounted on the bearing shaft with the vanes facing rearward. FAN BLADE IDENT. CHART pagt 6K-5 6K-5 6K-5 6K-6 6K-7 balancer.V-8 COOLING SYSTEM . The 15 pound pressure cap used raises the coolant boiling point approximately 46°. The pressure valve is held against its seat by a spring of predetermined strength which protects the radiator by relieving the pressure if the pressure should exceed that for which the radiator is designed. The pump is sealed against coolant leakage by a packless non-adjustable seal assembly mounted on the pump cover in position to bear against the impeller hub. The bearings are permanently lubricated during manufacture and sealed to prevent loss of lubricant and entry of dirt. Coolant flows through the inlet passage to the low pressure area at the center where it then flows rearward through three openings in the impeller. Fig. the coolant flows into the intake manifold water passage from the forward port of the cylinder heads to the thermostat housing and thermostat by-pass. open at all times. Vanes on the rotating impeller cause the coolant to flow radially outward through two discharge passages cast in the engine block. These passages deliver an equal quantity of coolant to each cylinder bank water jacket. During cold engine operation when the thermostat is closed. The engine fan and pulley(s) are bolted to the pump shaft hub at its forward end.L-6 FAN WATER PUMP ENGINE COOLING SYSTEM The engine cooling system is the pressure type with thermostatic control of coolant circulation. a thermostat bypass. The cooling system is sealed by a pressure type radiator filler cap which causes the system to operate at higher than atmospheric pressure. The pump shaft and bearing assembly is pressed in the water pump cover. A pellet type thermostat housed in the forward (outlet) end of the intake manifold controls the circulation of water through the engine radiator. Page 6K-1 6K-1 6K-3 6K-3 6K-5 Subject REMOVAL INSTALLATION THERMOSTAT THERMOSTATIC VACUUM SWITCH-K-19 . 6K-2) The coolant is circulated by a centrifugal pump mounted on the front cover which forms the outlet side of the pump. Thus both the fan and pump are belt driven by a crankshaft pulley bolted to the harmonic . (Fig. (177°-182°F) coolant is directed to the upper tank of the radiator.

6K-2 Engine Cooling Figs. 6K-2A and 6K-2B Engine Coolant Flow (V-8 Engine) .

The fan blades and pulley can be removed without disturbing the water pump or radiator. 6 K . On air conditioned equipped cars it will be necessary to detach fan shroud and slide it back over the fan. .Engine Cooling 6K-3 Fig.3 ) Engine Coolant Flow (L-6 Engine) thermostat to the radiator. Coolant then flows through the coolant outlet and the pellet-type NOTE: For fan blade usage. refer to FAN BLADE IDENTIFICATION CHART. Located in the coolant outlet at the front of the cylinder head is the outlet to the heater core from beneath the thermostat. When the first two bolts are removed.5 ) The centrifugal-type water pump contains an impeller which turns on a steel shaft which rotates in a ball bearing. NOTE: If belt tension on pulley is not released. FAN (Figs.4 and 6 K . replace with aligning studs. During engine warm-up. the fan can be removed without disturbing the pulley by removing four attaching bolts. Above the pump inlet from the radiator is the inlet from the heater core. A bellows-type seal is seated in the water pump body between the bearing and impeller. The water pump discharges coolant into the water jacket chamber between the front face of the block and the number one cylinder. The inlet side of the pump is connected to the lower radiator tank by a hose. Coolant then flows through the block toward the rear. when the thermostat is closed. Some coolant is directed through a small hole in the cylinder head gasket to an area around each spark plug. 6K-3 COOLING SYSTEM CIRCULATION L-6 ENGINE (Fig. 6 K . passing through two large cast openings into the cylinder head to cool the valve seats and forward to the front of the head. The tension of the belt will keep the pulley in position. water is redirected to the engine.

6K-5 Fan Installation (L-6) .6K-4 Engine Cooling Fig. 6K-4 Fan Installation (V-8 Engine) Fig.

If new coolant is used. (Fig. Remove the thermostat and place in water 10° below temperature indicated on the valve. If thermostat checks satisfactorily. NOTE: On L-6 engines. re-install. see Section 0. lbs.6 Water Pump Cross Section ( V . THERMOSTAT The thermostat consists of a restriction valve actuated by a thermostatic element. Install the pump assembly. 2. Remove thermostat housing bolts and r e move water outlet and gasket from thermostat housing.6 Engine) 4. Torque fan to pump bolts to 20 ft. Under this condition the valve should open fully. On air conditioned equipped cars. 3. Installation 5.7 W a t e r Pump Cross Section ( L . using a new housing gasket. Loosen pulley b e l t s and remove fan and pulley. Remove water pump attaching bolts. 2.fr Engine Cooling 6K-5 Fig.8 Engine) WATER PUMP (Figs. This is mounted in the housing at the cylinder head water outlet above the water pump. then position ± e gasket on the housing. 2. . PERIODIC MAINTENANCE for recommended coolant. r e move the clutch and fan assembly and pulley. 7. Remove radiator to water outlet hose. 4. Inspect thermostat valve to make sure it is in good condition. Torque nuts to 20 ft. Drain radiator. On air conditioned equipped cars install pulley and fan and clutch assembly. Disconnect heater and bypass hose and lower radiator hose from pump. 8. 6. and 5/16" bolts to 25 ft. lbs. Use oil on the self-tapping bolts. 6 K . 5. Submerge the valve completely and agitate the water thoroughly. lbs. 6K-6 and 6K-7) Removal 1. With valve completely submerged and water agitated thoroughly. 3. 6K-8) 3. the valve should close completely. Install pulley belt(s) and adjust belt tension using Tool BT-33-70-M. Install pulley and fan. Refill cooling system. 4. pull the pump straight out of the block to avoid damage to impeller. lbs. 1. Fig. Thermostats are designed to open and close at predetermined temperatures and if not operating properly should be removed and tested as follows: 1. Place thermostat in hot water 25° above the temperature stamped on the thermostat valve. Apply a thin coat of 1050026 Sealer to the pump housing to retain the gasket. 6 K . Torque self-tapping bolts to 13 ft.

When engine temperature is above 230°. This change from ported to fun vacuum advance at idle improves idle cooling If a heating problem exists at idle speeds only] disconnect the distributor vacuum hose at thermostatic switch. a thermostatic vacuum switch is used to increase ignition timing advance at idle when higher coolant temperatures are encountered. If engine temperature is above 230° and vacuum is present at port " D " . there should be no vacuum at this port at idle. 6K-8 Water Pump Installation (V-8 Engine) Fig. 6K-9 Thermostatic Vacuum Switch (K-19) . THERMOSTATIC V A C U U M SWITCH DIAGNOSIS K-19 (Fig.6K-6 Engine Cooling 9. 6 K . At temperatures below 230°. check distributor advance. Refill cooling system. Fig.9 ) If equipped with air conditioning. there should be vacuum at the switch port " D " at idle.

In. A.C.C. K19 425 Cu. (L-6) A. A. (L-6) Exc. In. K19 250 Cu. 4 18" Number of Blades 4 Diameter 18" Identification Marks 622 (Painted on Blade) None 6 19" H (Stamped On Front of Hub) None None 6 5 19" 18" .Engine Cooling 6K-7 FAN BLADE IDENTIFICATION CHART Engine Usage 250 Cu. In. & K19 400 Cu.C. In. In. A. Exc.C. 330 Cu. & K19 425 Cu. Exc.C. 400 Cu. A.C. 425 Cu. K19 & A. Exc. A.C.C. & K19 330 Cu. In. In.C. K19 & A. In. 330 Cu. K19 & A.C. Exc. K19 Exc. Exc. In.C. A. A. 400 Cu. In. In.

6K-8 Engine Cooling .

2. Cars delivered in California use a closed ventilation system and all others use the standard system. This pressure can cause the engine to blow out oil through the engine seals and gasket. The remainder of the system is the same for both standard and closed ventilation. Start the engine and adjust idle. When the engine is stopped the valve is closed and prevents engine fumes from entering the manifold. (Front of the carburetor for the four barrel and the r e a r of the carburetor for the two barrel. The crankcase pressure is low at this time and requires very little venting. Engine vacuum then draws the fumes up through a spring loaded valve into the intake manifold at the base of the carburetor. The closed ventilation systems oil filler cap is plugged so no air can be drawn through it. CRANKCASE VENTILATION VALVE DIAGNOSIS If sludging of the valve occurs it will not operate and the valve will be closed. 1. A quick check to see if rough idle is caused by the crankcase vent valve is to: 1. At highway speeds the valve varies in location with engine vacuum. 6L-1) The standard ventilation system receives its outside air through a filtered oil filler cap. Connect tachometer to the engine. Air goes through a screened flame a r r e s t e r into a hose to the valve cover (left side of engine). A plugged system will definitely cause a rough idle. The fumes from the crankcase and valve cover are drawn through a spring loaded valve into the intake manifold by vacuum and burned in the combustion chamber. high engine vacuum pulls the valve up against spring pressure and seats the valve. L-6 CRANKCASE VENTILATION SYSTEM (Fig. V-8 CRANKCASE VENTILATION SYSTEM (Fig. . VENTILATION VALVE DIAGNOSIS . The air intake for this system is obtained from the filtered side of the carburetor air cleaner. At idle. 6L-4 6L-4 6L-5 6L-5 6L-6 6L-10 CRANKCASE VENTILATION SYSTEM (K-20) Description The purpose of the crankcase ventilation system is to burn crankcase vapors and prevent them from reaching the outside atmosphere and contaminating the air. This limits the amount of fumes which can be drawn into the intake manifold. 6L-2) The difference between the two systems is the standard system receives intake air through a breather on the valve cover and the closed system receives air drawn from the snorkel end of the carburetor air cleaner to the filter and flame arrester on the left valve cover. through a calibrated orifice creating a smooth idle. 2. 4. CRANKCASE VENTILATION VALVE The spring loaded valve serves four purposes. . From here air goes through the left valve cover and is circulated in the engine crankcase. The valve is in a centering position allowing a greater area for fumes to pass through.) Both closed and standard systems use a plug type oil filler cap.(K-19 & K-20) Crankcase Ventilating Systems 6L-1 CRANKCASE VENTILATING SYSTEM (K-19 & K-20) 33 THROUGH 86 SERIES CONTENTS OF THIS SECTION Subject CRANKCASE VENTILATION SYSTEM (K-20) DESCRIPTION L-6 VENTILATION SYSTEM V-8 VENTILATION SYSTEM CRANKCASE VENTILATION VALVE . This is necessary because at highway speeds crankcase pressure is high and more air and ventilation are needed to burn crankcase fumes. This will cause high crankcase pressure at highway speeds. Page 6L-1 6L-1 6L-1 6L-1 6L-1 6L-1 Subject AIR INJECTION REACTOR SYSTEM (K-19) DESCRIPTION PERIODIC MAINTENANCE PUMP REMOVAL PUMP DISASSEMBLY AND ASSEMBLY DIAGNOSIS Page . In case of a backfire the valve is forced closed. 3.

6L-2 Crankcase Ventilating Systems (K-19 & K-20) .

(K-19 & K-20) Crankcase Ventilating Systems 6L-3 .

If the valve is working properly. two check valves and hoses. separate from the Crankcase Ventilation System It is designed to reduce air pollution caused bv engine exhaust gasses by "treating" the unburned hydrocarbons and carbon monoxide as they are expelled from the combustion chamber into the exhaust manifold. For Ventilation Valve maintenance recommendations. two manifolds. You should be able to hear the valve click shut when clamping off the line and releasing it several times. Distributor vacuum AIR INJECTION REACTOR SYSTEM ( K . The Air Injection Reactor System consists of an air filter. 6L-0 Vacuum Hose Routing . refer to GENERAL INFORMATION AND PERIODIC MAINTENANCE. 4. compresses clean filtered air which is distributed into the exhaust port of each cylinder. air bleed control valve. intake bleed valve. NOTE: This system does not reduce the danger of inhaling any concentration of carbon monoxide in a confined area. SECTION 0. the engine rpm will drop approximately 50 to 60 rpm. air pump.6L-4 Crankcase Ventilating Systems (K-19 & K-20) 3. producing a "treated" exhaust that is below the maximum allowable level for air pollution. A sealed bearing pump. There will be no change in engine rpm if the valve is sludged up and restricted.1 9 ) CARS DELIVERED I N CALIFORNIA ONLY) DESCRIPTION The Air Injection Reactor System is entirely Fig. If the valve is stuck open. NOTE: All carburetors for this system have ported spark (vacuum for the distributor is taken above the throttle valves). the engine rpm will drop off more than 60 rpm. driven by the engine. Clamp off the hose that goes from the valve to the carburetor base. Here it combines with the unburned hydrocarbons and carbon monoxode at high temperature causing a chemical reaction.

refer to A/C. Fig. A/C equipped cars. in. 6L-2. This valve is controlled by intake manifold vacuum and is required to prevent exhaust system backfires on deceleration. It also prevents back flow of exhaust gases through the system if air pump flow stops due to a broken belt or pump failure. 6L-3 Air Injection Reactor System Installation (330 cu. Disconnect hoses at pump. engine) . The air intake bleed valve injects air into the intake manifold. Fig. Remove filter element.000 miles (more often under dusty conditions). in. For installation of K-19 pump. dip in SAE 10W-30 oil and squeeze to r e move excess oil. The check valve is in operation only when exhaust manifold pressure exceeds pump pressure. 6L-0) The air pump compresses air drawn in through a silencer and filter. AIR INJECTION PUMP Removal 1. 6L-3 and 6L-4 illustrates the installation layouts for V-8 engines. The air pump and valves require no special maintenance other than the normal belt inspection and adjustment. This change from ported to full vacuum advance at idle improves idle cooling. engines and 425 cu. A relief valve in the air pump regulates pump pressure. The control valve will not let air into the intake bleed valve while at idle speeds. The pump forces air through a check valve into each engine exhaust port. On deceleration. momentarily as the throttle is closed.(K-19 & K-20) Crankcase Ventilating Systems 6L-5 Hvance is dependent on throttle opening. use a thermostatic vacuum itch t 0 increase ignition timing advance at idle when higher coolant temperatures are encountered. in. engines equipped with air conditioning. Section 1. (Fig. All 400 cu. L-6 engine does not use a control Refer to Fig. NOTE: valve. 6L-1 for L-6 engine system layout. PERIODIC MAINTENANCE The Air Injection Reactor System polyurethane filter (V-8 only) should be cleaned every 12 months or 12. the mixture in the intake manifold is too rich to burn and ignites when combined with the injected air in the exhaust manifold. wash in kerosene.

Remove rotor ring and carbon seal. 3. Move pump until belt is tight using BT-33-70-M. engine) 2. Discard carbon seal. Clamp pulley hub in vise as shown in Fig. Connect hoses and tighten clamps. . 6L-6 and remove the four housing end cover bolts. Installation Disassembly (Fig. 5. Remove bracket to pump mounting bolts and remove unit from car. 6L-7) 4. (Fig. Pull the vanes out of the rotor. 1. If hose is connected to the long tube. NOTE: The long tube is the silencer and air inlet. 2.6L-6 Crankcase Ventilating Systems (K-19 & K-20) Fig. 6L-5) 1. Remove pulley. 6L-4 Air Injection Reactor System Installation (425 cu. Tighten mounting screws. Do not clamp or pry on the aluminum housing. Connect air pump inlet hose to short outlet tube on air silencer. 7. 2. Do not pry on the aluminum 3. 3. NOTE: housing. 6. Position pump assembly on mounting bracket with holes lined up and install bolts loosely. 4. six rotor ring retaining screws Allen wrench. 5. 6L-8) Do not remove the bearings from the rotor. Install pump belt over pulley. NOTE: Do not submerge in solvent. Remove the housing end cover by tapping with a soft (plastic) hammer on the boss of the large dowel pin and pull straight up. Mark an alignment and rotor between two little ex(Fig. Remove the with a 5/32" on the ring haust holes. in. noise will occur and dirt will be drawn into the air pump. damage to the permanently packed bearings may occur. Loosen bracket to pump mounting bolts and remove pump belt. Clean off the outside area of the pump.

Support the ring adequately to avoid distortion and press out of rotor ring. Wash out the six vane bearings and r e a r bearing with a cleaning solvent and repack with 1050525 Grease. Carefully pull out the carbon shoes with needle nose pliers and remove shoe springs.(K-19 & K-20) Crankcase Ventilating Systems 6L-7 Fig. and the bearing and cover assembly must be replaced. If the front bearing or seal is to be replaced. CLEANING A N D INSPECTION To clean the rotor and housing assembly use only compressed air to blow out accumulated dust. 6L-10. 6L-6 Clamping Pump In Vise Fig. Fig. 6L-5 Air Pump Exploded View 8. NOTE: No further disassembly should be attempted as the rotor and housing are matched parts. (Fig. 6L-9) 10. These blemishes indicate r e a r bearing failure. Inspect the rear cover ground inner bearing race for grooves or scratches. The relief valve may be removed. using a suitable puller as shown in Fig. 9. The rear bearing may be replaced by pressing it out of the rotor ring. Rear bearing failure is also indicated by the absence of grease in the bearing. 6L-7 Removing Rotor Ring . caked grease. the rotor and housing assembly is to be replaced.

6 L . This washboard condition is normal. All corners of the vanes should be square. Damaged shoes must be replaced and springs positioned as described in PUMP ASSEMBLY. place the vane with even cuts to both ends and start the lower bearing over the dowel rod. a new vane assembly and cover assembly are required. Turn remaining vane. Inspect the vane pivot pin.8 Removing Vanes From Rotor Fig. Assembly 1. Grooves.1 0 Removing Relief Valve discoloration of bearing cage or rollers falling out of cage. Inspect the carbon shoe surface contacting the vane. 6L-9 Pressing O u t Rear Bearing Fig. Using a 3/8" dowel. scratches or discoloration indicate vane bearing failure. Inspect the vanes for chips and cracks. long end down Fig. The shoes will have small grooves from action of the thread structure of the vanes. Broken edges require that the vanes be replaced.1 1 I n s t a l l i n g Vanes i n Pump . If bearings have failed.6L-8 Crankcase Ventilating Systems (K-19 & K-20) Fig. notice their shapes. This pin has been precision ground. One vane has even cuts to both ends. but chipped or broken shoes are not. 6 L . 6 L . Two vanes are longer on one end than on the other. Before installing the vanes in the rotor.

When properly installed. a V-shape will be formed with the wide part of " V " facing the assembly pin of the vanes. Install end cover bolts and torque bolts to 10 ft. Coat the six ring screws with a thread sealer. Insert the three shoe springs into the deeper shoe slots. Curved portion of the spring is nearest the shoe. 6L-13 Installing Rear Bearing 9. Install carbon shoes with flat side to seat in slot and taper edge to face the vane. P r e s s the rear bearing into the ring lettered end up. 6. 6L-12) Notice the size of the shoe slots. Three are cut deeper. 6L-11) Leave the dowel assembly pin until later. 3. (Fig. Align the two dowel of the housing with the end cover holes. the into pins one Fig. . (Fig. such as Loc-Tite or its equivalent and torque to 37 in. (Fig. Push the spring flush ox beneath the rotor surface. Push the vanes into the rotor with one vane contacting the stripper. 2. lbs. 6L-14) Remove the assembly dowel pin from vanes. large and one small hole. 6L-13) Install the ring and bearing assembly aligning alignment marks. 6L-14 Installing Ring and Bearing Fig. This will make all ends the same height when all the way on the dowel rod. 5. 6L-12 Vane and Shoe Location and start the lower bearing over the dowel rod. Position a new carbon seal (gasket) with the two elongated holes directly over cavity of rotor.(K-19 & K-20) Crankcase Ventilating Systems 6L-9 Fig. Install the end cover pivot pin the vane bearings. Clamp the pump drive hub in the vise. lbs. (Fig.

do not pry on the housing. Relief valve failure will cause excessive noise. Excessive Pump Noise Check the drive belt tightness. The entire length of the hose system should be inspected. but swing the pump into proper position by hand so the belt is tight (use BT-33-70-M). Failure of a r e a r bearing is identified by a continuous knocking noise. With the pump running. bearing noise. Check that hoses are not touching other parts of the car. Lightly touch the vane ends and tips with emery cloth where they show grooves worn from the housing. 6L-15 Installing Relief Valve 10. under any conditions. Determine if all hoses are connected and have not vibrated free.) f. i . Extreme belt tension will damage the pump. DIAGNOSIS 1. g. Check belt tightness. Air leaks around clamps can be located in the same manner or by daubing soap water on connections in question. Any air leaking will bubble soap water. If the belt needs tightening. and the valve must be replaced. A "chirping" or squeaking noise is most likely associated with vane rubbing in the housing bore. Vane "chirping" is intermittent and is most noticeable at low speed. However.) h. Following pump disassembly. a rolling sound. if bearing noise increases to an objectionable level at certain speeds. remove the r e a r cover. If excessive noise is still present. check the entire system for leaks in the hoses and around clamps. is noticeable at all speeds. the pump must be disassembled. If roughness or bumps are felt. be taken in the a.6L-10 Crankcase Ventilating Systems (K-19 & K-20) d. use a suitable protecting plate over the valve and tap with a hammer until the valve shoulders on the housing. 2. 6L-15) NOTE: Care must be taken not to distort the aluminum housing. the bearing may have to be replaced with a new bearing to eliminate the noise. e. Such a noise requires further inspection of the pump and removal from the car. (Fig. pry on the . If additional wear-in does not eliminate " c h i r p " . remove the three vanes. proceed with the following steps in the order given: a. With the pump removed from the car (See PUMP REMOVAL) rotate the drive hub three-quarters of a turn forward and onequarter of a turn backward. breaks in hoses can be located by feeling for air blowing through any holes. Frequently vane " c h i r p " may be eliminated by increasing pump speed. allowing the vanes additional wear-in time. As the pump operates at engine idle speed. Check the pump relief valve. (See PUMP DISASSEMBLY and ASSEMBLY for correct procedure. Bearing noise is easily distinguished from vane "chirping". If it is determined that pump is not delivering air ence of air flow by removing the following steps should order given: the air injection (determine presan exhaust hose). Vane "chirping" is most noticeable at low speed and is heard intermittently. In tightening belt. do not. Check that the pump mounting bracket is securely fastened. Care must be taken to keep foreign material from the bearings. (See PUMP DISASSEMBLY and ASSEMBLY for correct procedure. b. Inoperative Pump Fig. To install relief valve. This sound does not necessarily indicate bearing failure. Failure has occurred if air escapes from the valve at engine idle speed. c.

Determine if all hoses are connected and have not vibrated free. bleed valve should draw air in for one to two seconds only. If the intake bleed valve is stuck closed. (Use BT-33-70-M) Extreme belt tension will damage the pump. .(K-19&K-20) Crankcase Ventilating Systems 6L-11 housing. Engine should be smooth when it returns to idle. it will continue to draw air after one to two seconds and engine idle will be extremely rough. If the valve is leaking or stuck open. a. Flash throttle. 6. With car in neutral. If the valve is stuck closed. a. With engine speed at 1000 rpm. Plug both pump outlets. Remove check valve and blow through valve. no air will pass to the intake bleed valve and the engine will backfire on deceleration. b. it will draw in air and engine idle will be extremely rough. Disconnect 3/16 ID vacuum hose from bleed valve and p l u g hose end. Inoperative Control Valve With hose connections secure. If each step in attempting to find the cause of no air delivery fails. b. 4. flash throt- tle. Inoperative Intake Bleed Valve With hose connections secure. 5. The entire length of hose system should be inspected. Air should blow from relief valve. (Engine will backfire on deceleration) If bleed valve is stuck open. With engine at idle there should be no blow through control valve. it will draw no air. an inoperative check valve can cause burned hoses from manifold to pump by exhaust back flow. flash throttle. a. As the pump operates at engine idle speed. Air should pass through valve from pump side only. Flash throttle. If the valve is stuck in the open position. Disconnect hose between intake bleed valve and control valve. b. the pump must be removed and disassembled. the intake bleed valve should not draw in any air. Engine should be smooth when it returns to idle. Inspect hoses. c. 3. d. b. Inoperative Relief Valve A relief valve stuck shut can cause pump failure and/or a burned exhaust system. Check the entire system for leaks in the hoses and around clamps. a. Disconnect hose between control valve and intake bleed valve. but swing the pump into proper position by hand so the belt is tight. air should flow through the control valve. engine idle will be rough for three seconds after start or when throttle is flashed. run engine 1000 rpm. breaks in hoses can be located by feeling a i r blowing through any holes. Plug valve inlet (15/16" diameter) and engine idle should return to normal. Inoperative Check Valve If pump or belt fails.

6L-12 Crankcase Ventilating Systems (K-19 & K-20) .

. 6M-109 4MV Carburetor Fig.L. ADJUSTMENT SPECIFICATIONS Fig. MODEL 4MV 34-36-38-52-54-56-58-84-86 Series Refer to Page 6M-23. For the step by step disassembly and assembly procedure. MODEL BV 33 & 35 Series-Except Air Injector Reactor System Subject DESCRIPTION REMOVE AND INSTALL DISASSEMBLY CHOKE AIR HORN FLOAT BOWL THROTTLE BODY CLEANING AND INSPECTION Page 6M-1 6M-2 6M-2 6M-4 6M-4 6M-4 6M-5 Subject ASSEMBLY Page THROTTLE BODY FLOAT BOWL AIR HORN FLOAT LEVEL ADJUSTMENT . 6C-6 On Car Adjustments-V-8 CARBURETOR USAGE CHART Refer to Page 6M-43. ADJUSTMENT SPECIFICATIONS . .6 Fig.. in. and is used on all 250 cu. except those equipped with K-19 (Air Injector Reactor System) for both a u t o m a t i c and manual transmissions. Refer to Page 6M-10. refer to the appropriate sub-section (Model BV. YF. ADJUSTMENT CHOKE ADJUSTMENTS (ON OR OFF CAR) . MODEL 2GC 34-36-38-52-56-58 Series Refer to Page6M-16.. . 2GC and 4MV). FLOAT DROP. 6M-1) The Model BV carburetor incorporates several distinct features. downdraft model with provision for automatic choke mounted on the exhaust manifold.Model BV Carburetion 6M-1 CARBURETION ALL SERIES CONTENTS OF SECTION SPECIFICATIONS The specifications for Model 2GC and Model 4MV carburetors are found at the end of this section. 6M-41 6M-42 6C-3 6C-5 MODEL BV CARBURETOR GENERAL DESCRIPTION The Rochester Model BV carburetor is a single barrel. engines. It has a concentric float bowl. 6C-5 On Car Adjustments. .. 6M-6 6M-6 6M-6 6M-7 6M-7 6M-7 6M-8 6M-9 MODEL YF 33 & 35 Series-Equipped with Air Injector Reactor System. (Fig. . 6M-108 2GC Carburetor Fig.

to a point where the cold engine will run without loading or stalling. Connect fuel and vacuum lines. Power.3 ) 4. 5. The Model BV carburetor incorporates the six systems of carburetion: Float. Engine heat cannot be directly transmitted from the float bowl into the main well area. the fuel level is below the nozzle spill joint at all times. 3. . remove two diaphragm bracket screws and r e m o v e vacuum b r e a k diaphragm assembly. 2. 6M-1 Model BV Carburetor which completely surrounds the main bore of the carburetor. Disconnect choke rod. On the Model BV carburetor the choke thermostatic coil is located on the exhaust manifold and is connected directly to the choke valve shaft by a connecting rod. in conjunction with the centrally located discharge nozzle. 2. 2. Position carburetor over mounting studs. 3. Remove air cleaner and gasket. (6M-2) REMOVAL (Fig. Another feature of the carburetor is the unique design of the main well assembly. Pump. 4. Remove choke shaft lever screw (diaphragm side). and Choke. Connect choke rod.6M-2 Model BV Carburetion Fig. This assembly contains the main metering jet and power valve. The choke rod can now be removed from the fast idle cam by 1. Disconnect accelerator rod. INSTALLATION 1. Disconnect choke vacuum break hose at diaphragm unit and from pipe in throttle body. prevents fuel loss on inclined roads. Regardless of the angle the car assumes. Disconnect fuel and vacuum lines. lbs. Remove the two attaching nuts and remove carburetor. Then the fast idle cam and choke rod can be r e moved from upper choke lever by carefully rotating assembly upward and sliding end of rod out of upper choke lever. Idle. The exhaust-mounted choke coil provides excellent choke response to supply the correct fuel mixtures to the engine during the warm-up period. The design of the float bowl. 6 M . 3. torque to 18 ft. Clean throttle body and manifold gasket surfaces and install new gasket over studs. Remove fast idle cam attaching screw. 5. just after starting. Install attaching nuts. Main Metering. It is attached to the carburetor air horn and is suspended in the float bowl. CARBURETOR DISASSEMBLY CHOKE 1. A vacuum diaphragm unit mounted on the carburetor air horn opens the choke valve. install air cleaner and gasket.

Model BV Carburetion 6M-3 Fig. . Choke shaft and lever assembly can now be removed from air horn. 6M-2 BV System rotating cam over end of rod. remove stake on the end of choke valve screws. To remove choke valve. Then remove the two choke valve attaching screws from the choke shaft and pull upward on choke valve to remove from shaft. 4.

NOTE: Large open end of filter element always faces the fuel inlet nut. FLOAT BOWL 1. Throttle body and gasket may now be removed. Then remove filter. Remove the pump plunger from |he float bowl by pulling straight upward. AIR HORN 8. Remove air horn gasket. NOTE: Use care when removing power valve so as not to lose small spring and ball. 5. Remove hex head power valve check ball r e tainer from bottom of support. inverted. 5. filter spring and gasket between filter element and back side of inlet nut. Remove four air horn attaching screws. Place carburetor bowl with suction tube projected over edge of flat surface and remove two throttle body attaching screws. Using a pair of long nosed pliers. 6. Remove float hinge pin and lift float assembly from air horn. Remove main metering jet from bottom of main well support. Remove idle mixture adjusting needle and . 6M-2A BV Carburetor Assembly Note position of choke trip lever in relation to upper choke lever tang for ease in reassembly. 1. Pump discharge spring and ball may now be removed by inverting bowl and shaking into palm of hand. The anti-bubble screen located inside the main well should not be removed. 7. Remove two hair pin clips from pump link and then remove pump link from throttle lever and pump plunger rod. 2. (6M-4) 2.6M-4 Model BV Carburetion Fig. Remove float needle seat and gasket with 1/2" bit screwdriver or special needle seatremoving tool. THROTTLE BODY 1. NOTE: Do not remove vacuum break suction tube from throttle body. Clean and blow out dry with compressed air only. 3. Fig. 6M-3 Removing Float then remove the main well support from air horn. Remove screw at base of main well support. 3. Remove pump return spring from bottom of pump well. on a flat surface. NOTE: Do not remove idle pick-up tube from air horn as it is pressed in place. 4. Float needle may now be removed. 9. remove pump discharge guide. Remove fuel filter inlet nut and gasket with 1" wrench. then remove power valve spring and ball. Remove power piston and power piston spring from air horn. Place air horn. Lift air horn straight up from bowl so as not to damage float. (6M-3) 4.

Plastic vacuum break diaphragm unit should not be immersed in any cleaner. defective part must be replaced. 7. 4. NOTE: Do not pass drills or wires through calibrated jets or orifices as this may enlarge orifice and seriously affect carburetor calibration. Check all parts for wear. T h r o t t l e Body Gasket 2 3 . 13. Remove idle stop screw from throttle lever if necessary to replace. Bowl . 12. Vacuum Diaphragm Hose 2 5 . CLEANING A N D INSPECTION 1. NOTE: Especially the following: Fig. A i r Horn Gasket 17. a. Pump Link 2 2 . Pump Discharge Check Assembly 18. BV Carburetor . 10. 14. Clean in clean solvasol or equivalent. Idle M i x t u r e N e e d l e and Spring 2 4 . If wear is noted. Fig. Fuel I n l e f F i l t e r Assembly Va cuum Diaphragm Assembly Choke Lever Choke V a l v e Choke Lever Choke Shaft Choke Rod 8. 3. 6 M . NOTE: Pump Plunger and any synthetic or plastic parts should not be immersed in commercial carburetor cleaner. Thoroughly clean carburetor castings and metal parts in carburetor cleaning solvent. T h r o t t l e Body Assembly 2 6 . After cleaning. Pump Return Spring 2 0 . 9. A c c e l e r a t o r Pump 19. 2. 3. NOTE: Due to close tolerance fit of the throttle valve in the bore of the throttle body. blow all passages and castings with compressed air and blow out all parts until dry. 6. 5. Power V a l v e Assembly 16. 11. 2. Check float needle and seat for wear.Exploded View 2 1 .5 1. 2. 6 M .Model BV Carburetion 6M-5 do not remove the throttle valve or shaft from the throttle body.4 Removing Pump Discharge Guide spring. Fast I d l e Cam A i r Horn Power Piston and Spring N e e d l e and Seat Assembly Float Float Pin M a i n W e l l Support Main Metering Jet 15.

4. Check pump plunger vent ball to make sure it is free inside pump plunger head. g. Back needle out 1-1/2 turns as a temporary idle mixture adjustment. Place new air horn gasket on top air horn. Install float needle seat and new gasket. replace it if necessary. a new vacuum seal can be installed after carburetor is completely assembled. if removed. Replace plunger if leather or synthetic rubber is scored. 4. If screen remains plugged. NOTE: Dog leg in pump link will face away from throttle shaft when installed correctly. using two screws and lockwashers. replace main well support. NOTE: If needed. Inspect pump plunger. hardened or damaged. attach throttle body to bowl. Attach pump link to pump plunger rod and throttle lever. Check throttle and choke shaft bores in throttle body and air horn castings for wear or out of round. Check idle mixture needles for burrs or ridges. ball should rattle freely. 2. replace it. If filter remains plugged. Clean all dirt or lint out of the fuel inlet filter. Install idle stop screw in throttle lever. Always use new gaskets in reassembly. 3. NOTE: Piston should ride free in cavity. Carefully insert p u m p discharge spring and guide on top of ball. d. check to be sure that all air horn and gasket holes are in line. Check relief spring for distortion. 2. 4. Tap the discharge guide lightly to seat flush with the float bowl casting. Install pump plunger assembly in bowl. e. using special tool or screwdriver with 1/2" bit. Screw idle mixture adjusting needle and spring into throttle body until it is finger tight. 6. Inspect for burrs on the power piston or a distorted power piston stem or spring. AIR HORN 1. making sure not to curl rubber during installation. h. c.6M-6 Model BV Carburetion CARBURETOR ASSEMBLY THROTTLE BODY 1. Check floats for leaks by shaking. . Using a new gasket. Fig. f. 6M-6 Installing Pump Discharge Ball FLOAT BOWL b. Check tank on float arm above float needle for wear and floats for dents. Install power valve ball (small steel ball). it should be replaced as it may upset engine idle during the engine warmup period. Install power piston spring and power piston in vacuum cavity. 1. Ends of link will protrude outward away from throttle body. 3. 5. 6M-6) NOTE: The pump discharge guide is installed correctly when it is at right angles with the pump discharge jet. 3. (Fig. If wear is noted on the steps of the fast idle cam. Thoroughly clean anti-bubble screen in main well. 2. Place pump return spring in pump well and bottom spring in well by forcing downward with index finger. Install 3/16" steel ball into pump discharge cavity. using two hair pin clips. Tighten screws evenly and securely. This may be done by shaking.

(Fig.casting. Recheck float level adjustment if float alignment is necessary. Tighten retainer securely. Assemble choke shaft into air horn from the throttle lever side. 6M-8 Float Drop Adjustment power valve spring. Install choke shaft lever to end of choke shaft (diaphragm side). Then tighten the two choke valve attaching screws securely and stake in place. measure the distance from the air horn gasket to the bottom of each float. 8. Large side of lever will With the air horn inverted and gasket in place. Tang on the choke lever should point towards air horn. filter element retaining in place with the fuel inlet nut and gasket. move the choke shaft horizontally to obtain . Check for free motion of power metering jet in main well COMPLETION OF CARBURETOR ASSEMBLY 9. 6M-7) Align floats by making sure they are parallel and centered in the air horn gasket cut-out. (Fig. 11. Attach main well support to air horn assembly and tighten attaching screw securely. next to the needle seat. Install four air-horn-to-float-bowl attaching screws and tighten evenly and securely. aligning flats on lever with flats on choke shaft. 6M-8) . Install upper choke rod lever on choke shaft. to obtain the specified dimension. Install choke valve into the slot in the choke shaft. RP trademark should face upward.Model BV Carburetion 6M-7 Fig. as shown. as necessary.020 clearance between the two levers. 5. Install air horn to bowl assembly. Tighten securely. FLOAT LEVEL ADJUSTMENT 1. Install main support. Place float needle in float needle seat.Level Adjustment Fig. NOTE: piston. Install two choke valve attaching screws. CHOKE ASSEMBLY 6. 7. 6M-7 Float. 3. Tang on the trip lever should be above the tang on the choke lever. as necessary to obtain specified dimension from the gasket surface to the bottom of the float with the air horn held in the upright position and the float hanging free. retaining with two attaching screws. Place float carefully in position with drop tang pointing downward towards air horn and install float hinge pin. 4. FLOAT DROP ADJUSTMENT Bend the float tang at the rear' of the float arm. filter relief spring. Install filter gasket inside fuel inlet nut. Bend the adjustment tang on float arm which contacts float needle. being careful to lower the air horn straight down so that the floats will not be bent during installation. 6. Install vacuum diaphragm unit and bracket to side of air horn. To insure proper end clearance between the choke trip lever and choke rod lever. and retainer in main well support. 5. 10. 2.

and screw on low step of cam. adjust using screwdriver. adjust rod so that specified gauge will fit between lower edge of choke valve and inside of air horn casting. 9. 7. then carefully insert the upper end of the choke rod into the upper choke lever. the idle vent valve should be open as specified. The steps on the fast idle cam should face towards the idle speed screw. adjust vacuum break as follows: Push the vacuum break diaphragm plunger in until seated. as needed. identification faces outward. 6M-9 Idle Vent Adjustment To insure correct initial choke valve opening. In this position. Install connecting rod to vacuum break diaphragm plunger by rotating end of rod so squirt on rod enters notch in plunger. To adjust. 3. 6M-10 Vacuum Break Adjustment Fig. Check clearance between air horn and vent valve. ends of rod face inward. just after engine starting. Install other end of rod into slot in choke lever. 6M-10) hang downward and part No. 6M-9) VACUUM BREAK ADJUSTMENT Fig. Install the choke rod to the fast idle cam as shown. 2. IDLE VENT ADJUSTMENT 1. (Fig. bend the connecting rod at the point shown. Install horseshoe clip in groove in rod end and pinch together. The dog leg of rod must face towards the idle mixture adjusting needle. Adjust by turning valve on top of air horn. Tighten securely. If necessary. Fig. (Fig. make sure the choke valve is held toward closed position so that the connecting rod is at end of the slot. Back idle speed screw out until free (choke open).6M-8 Model BV Carburetion 8. Attach the fast idle cam to the throttle body assembly with the fast idle cam screw and tighten securely. 6M-11 Choke Rod Adjustment . With idle rpm set to specification.

Choke Setting. bend rod as shown.. . Choke Rod Unloader Main Metering Jet Throttle Bore Vacuum Break 1-9/32" 1-3/4" 070" 1/2 to 1 Rod Dia. .1 1 ) AUTOMATIC CHOKE ADJUSTMENT With the idle screw resting on the second step of the fast idle cam and against the shoulder of the high step.060" S.. Hold the choke valve completely closed and pull up on thermostatic coil rod to the limit of its travel.T. (Fig.M. 350" 058" A. To adjust. 1-9/16" 140" A. 6 M . 6M-12) Fig.160" M. UNLOADER ADJUSTMENT Disconnect upper end of choke thermostatic coil rod from choke lever. 6M-13 Automatic Choke Adjustment the lower edge of the choke valve and the dividing wall of the air horn. .T.100" M. .T.T. bend the choke rod to obtain specified clearance between the lower edge of the choke valve and the dividing wall of the air horn. with the throttle valves held wide open.Model BV Carburetion 6M-9 Fig. Interference 090" A. NOTE: Make sure unloader arm does not interfere with fast idle cam screw after this adjustment.T. (Fig. 6M-13) Bend the unloader tang on the throttle lever as necessary to obtain specified dimension between MODEL BV SPECIFICATIONS AND ADJUSTMENTS Float Level Float Drop Idle Vent Auto.. The lower edge of the rod should be even with the top edge of the hole in choke shaft lever for maximum rod length while the rod should just line up with the hole for minimum rod length. 6M-12 Unloader Adjustment CHOKE ROD ADJUSTMENT (Fig.

Clean throttle body and manifold gasket surfaces and install new gasket over studs. Disconnect vacuum break link at choke lever by rotating vacuum break. low speed circuit. ADJUSTMENTS 3. 2. Place air horn up-ended on a flat surface and remove float hinge pin. Check the fuel bowl for evidence of dirt. 4. 3. Remove the two attaching nuts and remove carburetor. grit. 6. 3. The accelerator pump circuit and metering rod are mechanical and vacuum controlled. 4. inlet filter nut. Disconnect fuel and vacuum lines. Connect fuel and vacuum lines. Position carburetor over mounting studs. . 5. Remove air cleaner and gasket. 2. Connect choke rod. Install attaching nuts. filter and spring. then hold finger over pump discharge passage (to retain discharge needle) and operate the pump manually a few times to check Fig. 6M-12 6M-13 6M-13 6M-13 6M-14 The Model YF Carburetor with an automatic choke used in conjunction with a temperature sensing choke coil (mounted in a cast depression on the exhaust manifold) is used with the L. or metal particles in the fuel or in bottom of bowl. 5. The high speed circuit is controlled by a metering rod.6M-10 Carburetion Model YF MODEL YF CARBURETOR CONTENTS OF THIS SECTION Subject Page Subject Page DESCRIPTION REMOVE AND INSTALL DISASSEMBLY CLEANING AND INSPECTION ASSEMBLY BOWL AND THROTTLE BODY DESCRIPTION 6M-10 6M-10 6M-10 6M-11 6M-12 6M-12 ASSEMBLE AND ADJUST METERING ROD AIR HORN FLOAT ADJUSTMENT ASSEMBLE AIR HORN TO BOWL . 2. (Fig. lbs. Disconnect vacuum break hose at bowl and remove vacuum break assembly. 6M-25 Model YF Carburetor . 1. install air cleaner and gasket. Remove choke rod. DISASSEMBLY 1. INSTALLATION 1. Disconnect accelerator rod. torque to 18 ft. 6M-25) The Model YF Carburetor has the conventional float. REMOVAL 5. high speed circuit and accelerator pump circuit. Remove 6 air horn screws (3 from body to air horn then 3 from air horn to boyd) and lift air horn straight up from body (to prevent float damage). 4. Disconnect choke rod. Remove float needle seat using a wide screw driver.6 engine when the "Air Injection Reactor System" is used. and float needle. float.

Ordinarily. then compress upper pump spring(s).) 14. and passage restriction. Remove pump housing screws from housing and diaphragm. Compress lower spring. (Do not remove any pressed-in parts. check ball and needle. File staked ends of choke valve screws flush with shaft to prevent damage to shaft threads.Model YF Carburetion 6M-11 Fig. Empty the gas and remove pump discharge needle by up. 7. 4. 2. 6M27) 11. Loosen throttle shaft pump arm lock screw and remove arm and pump connector link. then slide shaft out of flange. 6M-26) 10. 9. 5. (Fig. If necessary. the carburetor flange and air horn are disassembled as far as is necessary during an overhaul procedure.ending carburetor bowl. 6M-27) 13. 11. 8. Upper Spring Retainer Lower Spring Screws Pump Housing Diaphragm Assembly 15. remove the spring retainer and lower pump spring. Remove idle mixture screw and 2 remaining body-flange attaching screws and remove body and gasket from throttle flange. (Fig. Remove metering rod from metering rod arm. 81—Pump and Metering Rod—Exploded V i e w Sea! Lifter Link Metering Rod Metering Rod Arm Idle Vent Assembly Retainer 7. (Fig. metering rod. 6M-26 Pump and Metering Rod Assembly operation of diaphragm. then remove screws and choke valve and slide choke shaft from housing. Remove diaphragm housing screws and lift out entire pump. Wash all metal parts in cleaning solvent and dry with compressed air. (Fig. CLEANING AND INSPECTION 1. and pump lifter link assembly. J2. 8. . 3. remove screws and throttle plate. metering rod arm. 6. 9. File staked ends of throttle valve screws flush with throttle shaft. If either condition exists. spring(s). 6M27) 12. Remove main metering jet and low speed (idle) jet. 10. and idle vent assembly. disassemble as follows: 1. then remove diaphragm shaft retaining ring and slide diaphragm assembly out of housing. The valve and shaft should not be removed unless shaft is binding or valve is damaged. 16. remove retainer. Fig. r e move idle vent screw assembly from lifter link.

a n d tighten lock screw. If idle vent screw assembly was replaced. 8. 10. Install pump connector link in throttle shaft pump arm. then install arm over throttle shaft. loosen lock screw. CAUTION: Do not use wire or other pointed instruments to clean drilled passages or calibrated openings. . Align diaphragm with holes in housing. guiding connector link end into pump lifter link. then install screws (4) through housing and thread into diaqhragm 2 or 3 threads. filter for chips. 6M-28) NOTE: Linkage must not bind in any throttle position. Install diaphragm assembly in place in carburetor body and tighten screws securely. Check all passages for clogging and blow clean with compressed air. adjust slightly and retighten screw. upper spring(s) and spring retainer onto pump shaft. Install throttle valve screws. Install pump discharge needle. Install low speed jet assembly metering jet. Fig. dents. then install lower pump spring and retainer. (Fig. 6M-29 shows the carburetor at this stage of assembly. If disassembled. with throttle valve closed. cracks or 7. (Fig. Adjust by bending metering rod arm. and main 1. ASSEMBLE AND ADJUST METERING ROD 6. Check f u e l clogging. Check float needle and seat for wear and r e place if necessary. 3. Install idle adjustment screw and spring lightly to its seat. 8. If binding occurs. 12. NOTE: Refer to Fig. 2. 6M-27 for pump and metering rod assembly. 13. 3. 4. 6. 6M-28 Pump Connector Link Installation 9. 5. NOTE: Fig. support the shaft at the screwhead and stake the other end of the screws. then metering rod arm. wear at lip and hinge pin. ASSEMBLY 11. 6M-30) Metering rod arm should rest parallel on pump lifter link and metering rod eye should just slide over metering rod arm pin. Check choke valve and shaft for binding in air horn when assembled. Inspect pump diagragm for tears or holes and diaphragm housing for free intake check ball and clean passages. BOWL A N D THROTTLE BODY 1. and back out 1-1/2 turns as an initial adjustment.6M-12 Carburetion Model YF 2. NOTE: Damage or excessive wear in throttle shaft bores necessitates replacement of the throttle flange to maintain position of drilled passages to throttle plate. 2. 5. 4. Install throttle valve with lettering toward manifold side of flange and part number opposite idle port. Assemble pump lifter link. Assemble diaphragm and shaft into pump housing and install retaining ring on shaft. Place metering end through metering jet then bottom rod in casting and. slide shaft into flange. Assemble throttle flange to body casting using a new gasket. install new assembly onto pump lifter link. press down on upper pump spring until pump bottoms out. Check floats for leaks. Check throttle flange for surface squareness and for slop in shaft bores. 7.

Model YF Carburetion 6M-13 Fig. 1. 6M-32 Float Drop Adjustment . Fig. 6M-29 ASSEMBLE A I R Bowl and Throttle Body .Assembled HORN 1. Install choke rod and vacuum break assembly (if so equipped). filter and inlet nut using new gaskets. 6M-31 Float Level Adjustment 2. Invert bowl (the distance end of float). Install air horn assembly and 6 attaching screws (one long screw installed through flange and body into air horn). Install needle seat and gasket assembly. needle. Adjust by bending stop tab on float arm. (lug 6M-32) 3. Hold cover in upright position (allowing float to hang down) and measure float drop from cover to float at end opposite hinge. BOWL ASSEMBLE A I R H O R N T O Refer to specification chart r e a r of this section. 6M-31) Adjust by bending (not float arm) that r e s t s on 1. 3. ADJUST FLOAT Fig. float a n d float hinge pin with stop shoulder on hinge pin on side opposite carburetor bore. 6M-30 Metering Rod Adjustment Fig. Install air horn gasket. lip of float needle. 2. cover and measure float level between float and cover at free (Fig. Install fuel filter spring. 2.

2.015") between fast idle cam and boss on carburetor bowl. 6 M . 3. adjust using screw driver. 6M-36 Vacuum Break Adjustment 1. 6M-33 Idle Vent Adjustment Fig. 6M-34 Choke Rod Adjustment (Automatic Choke) ADJUSTMENTS Refer to SPECIFICATION CHART at the rear of this section. bend choke rod at offset to obtain a slight clearance (max. Check clearance between air horn and vent valve. . (Fig. 6M-35 Choke Unloader Adjustment Fig. 6M-34) .3 3 ) Fig. ADJUST IDLE VENT (Fig. Back idle speed screw out until free (choke open).6M-14 Carburetion Model YF Fig. ADJUST CHOKE ROD (FAST IDLE) With choke valve fully closed. This assures closed throttle valve. If necessary.

bend unloader tang on throttle a lever to obtain the specified clearance between the lower edge of the choke valve and the air horn wall.300' . (Fig. (Fig. 6M-34) CHOKE UNLOADER ADJUSTMENT With the throttle valve held wide open and the choke valve held toward the closed position with rubber band.035" 1/2 to 1 Rod Interference 260" . 6M-35) VACUUM BREAK ADJUSTMENT With the vacuum break arm held in against its stop and the choke valve held toward the closed position with a rubber band. index mark on fast idle cam must be at midpoint of fast idle tang on throttle lever. Bend fast idle tang up or down to adjust.36) MODEL YF SPECIFICATIONS AND ADJUSTMENTS Carb.Model YF Carburetion 6M-15 With choke valve fully closed. 6M. Choke Setting Unloader Choke Vacuum Break 4080S 1/2" 1-3/16" . (Fig. bend the vacuum break link to obtain the specified clearance between the lower edge of the choke valve and the air horn wall. Letters Float Level Float Drop Idle Vent Auto. Tag Ident.

float. To minimize fuel vapor formation in the carburetor bowl.6M-16 Model 2GC Carburetion MODEL 2GC CARBURETOR 3 4 . FLOAT SYSTEM (Fig. I B U SYSTEM (Fig.5 2 ) The idle system supplies the fuel required for normal curb idle. Fuel then enters the float bowl.5 8 SERIES Subject Page Subject Page THEORY OF OPERATION FLOAT SYSTEM IDLE SYSTEM PART THROTTLE SYSTEM POWER SYSTEM PUMP SYSTEM CHOKE SYSTEM CARBURETOR ASSEMBLY REMOVE AND INSTALL 6M-16 6M-16 6M-16 6M-17 6M-17 6M-17 6M-17 6M-18 6M-18 DISASSEMBLY CLEANING OF PARTS INSPECTION OF PARTS ASSEMBLY COMPLETION OF CARBURETOR ASSEMBLY ADJUSTMENT CHART CARBURETOR USAGE CHART 6M-18 6M-20 6M-20 6M-20 6M-21 6M-41 6M-43 THEORY OF OPERATION There are six basic systems used in the Model 2GC. part throttle. 6M-50 Carburetor Assembly Fig.3 6 . 6 M . 6M-51 Float System Fig. power.5 2 . raises the float and closes the needle seat. 6 M . off idle and low speed operation. an external vent opens when the throttle valves are in the idle position. idle. pump and choke.5 1 ) The 2GC carburetor employs a single float.5 6 . the float drops and opens the needle seat. As fuel is consumed. Fig. 6M-52 Idle System . maintaining correct fuel level in the float bowl under all operating conditions.

6M-54 . the speed of air entering the carburetor bore increases and raises the vacuum in the small venturi area. 6 M . offsetting the enrichening effects of the higher temperatures. a vacuum operated power piston and power valve provide additional fuel. the force of the thermostatic coil is opposed by air velocity against the offset choke valve and a vacuum piston and link assembly. When manifold vacuum drops below approximately 9" hg. Fig. the power piston spring forces the piston down to unseat the spring loaded power valve.Power System Fig.5 5 ) The accelerator pump provides the fuel necessary for smooth operation during acceleration by forcing additional fuel into the air stream.Model 2GC Carburetion 6M-17 where air venturi. 6M-53 Part Throttle System Cars equipped with factory installed A/C are equipped with an idle compensator to prevent stalling under prolonged "hot idle" conditions. To prevent a closed choke condition with a wide open throttle. 6 M . 6 M . a bi-metal strip lifts the valve off its seat allowing additional air to enter below the throttle valves.5 3 ) As the throttle valves open.5 6 ) Fig. When underhood temperatures rise. 6M-55 Pump System .5 4 ) When more power is needed or high speed driving is maintained. bleeds are provided. 6 M . and into the POWER SYSTEM (Fig. To maintain a more exacting air-fuel ratio during warm-up. CHOKE SYSTEM (Fig. The choke system is designed to work independently of the fast idle which provides a relatively short choking period with adequate fast idle for a cold engine. Fuel is then drawn from the float bowl into the main well. a tang on the unloader lever contacts the choke lever and holds the choke valve partially open to prevent a loading condition. A thermostatic coil closes the choke valve for cold operation and gradually releases the choke during the warm-up period. PART THROTTLE (Fig. This also provides an unloader to open the choke valve when starting a flooded engine. PUMP SYSTEM (Fig. permitting additional fuel to flow through the main well tubes.

Remove the float needle and seat and gasket using Tool BT-52. 7. If the pump lever and shaft or inner arm is to be replaced. reverse removal procedure and make adjustments outlined under ADJUSTMENTS (ON THE CAR). shield and vent. Remove throttle body to intake manifold nuts or bolts. 5. then lift the air horn straight up to remove. Remove the power piston by depressing piston stem and allowing it to snap free. To install. 4. Remove the retainer from the pump plunger shaft and remove pump plunger.6M-18 Model 2GC Carburetion Fig. CARBURETOR DISASSEMBLY AIR HORN 1. 9. then r e move the filter. Remove fuel inlet fitting and gasket. 6M-56 Choke System CARBURETOR ASSEMBLY REMOVE A N D INSTALL 1. Invert the air horn and place on a flat surface. Disconnect choke pipe. Disconnect linkage. 12. Disconnect vacuum lines. 11. Remove the eight air horn attaching screws. 3. Remove the idle vent valve retaining screw. loosen the set screw on the inner arm. (Fig. 7. Remove the air horn gasket. 6M-57 2GC Carburetor 2. (Fig. Remove carburetor. 6. Mount carburetor on Holding Fixture BT-3014 or J-5923-B. Remove retainer spring clip from the upper end of the pump rod at the pump lever and disconnect the upper end of the pump rod. 6M-58) 8. Fig. 5. 4. 6M-5a Air Horn . Remove retainer clip from the intermediate choke rod and unloader rod and remove the intermediate choke and unloader rods. Fig. float and needle assembly. 6M-57) 2. Torque carburetor to intake manifold nuts or bolts to 14 ft. 10. then remove the float hinge pin. 3. Disconnect fuel line from carburetor. 6. Remove air cleaner. lbs.

5 9 ) 1. 5. Remove the choke housing gasket. 6 M . NOTE: The cluster center screw is larger and has a gasket since it is located in the pump discharge passage. Remove baffle plate from choke housing. Remove the two choke housing attaching screws. 6M-60) 6. Remove main metering jets and power valve. Remove the choke piston attaching screw. Remove venturi cluster attaching screws and remove cluster and gasket. FLOAT BOWL (Fig. 1. then remove the choke housing with linkage. 6M-61 Throttle Body and Choke . then r e move the choke lever and shaft with linkage from the choke housing. Remove the fast idle cam attaching screw. choke valve shaft and unloader from the air horn. The idle mixture needle screws may be r e moved for cleaning or replacement. 4. then remove aluminum ball check from bottom of pump well. Remove the three choke cover attaching screws and retainers. 4. remove the pump discharge spring guide. 6 M .6 1 ) Fig. THROTTLE BODY A N D CHOKE LINKAGE (Fig. 6. 6M-60 Pump Discharge Guide 3. Invert float bowl and remove the three throttle body attaching screws. then remove the throttle body and gasket. (Fig. 2. then remove the spring and steel ball. If equipped with an idle compensator (factory installed air conditioned cars only) remove attaching screws and remove idle compensator and gasket. remove. 5. Using a pair of needle-nosed pliers. then remove the cover and gasket. then remove the choke valve. 2. the two choke valve attaching screws. pump inlet filter screen and pump plunger return spring.Model 2GC Carburetion 6M-19 13 If the choke valve or shaft is to be replaced. The piston can be removed from the link by removing the piston pin. 7. Fig. 3. then remove piston link and lever assembly. 6M-59 Float Bowl Assembly Fig. Remove baffle.

2. 2. then position the throttle body on the gasket and install the three attaching screws. housing and pump plunger should not be immersed in solvent. INSPECTION OF PARTS CLEANING OF PARTS The carburetor should not be cleaned in any solution other than a cold immersion type cleaner. then position the choke housing on the throttle body and install the two attaching screws. Replace if necessary. fast idle cam and throttle shaft lever. Inspect the idle mixture adjusting needles for burrs or ridges. 4. 6M-60) 2. Install the pump inlet (aluminum) ball and the pump return spring in the pump well. with linkage attached. Install the fast idle speed screw and spring in the lever. 1. Damaged beading may r e sult in air or fuel leaks at that point. Install the venturi cluster. 3.6 1 ) 1. 6 M . in the choke housing. replace with a new matched float needle. Inspect the throttle body to make sure idle passages and vacuum channels are open. 3.. FLOAT BOWL 1. Tighten screws evenly and securely. 7. Place a new gasket on the bottom of the float bowl with holes aligned. Tighten finger tight. If worn. (Fig. spring and guide in the passage in the venturi cluster mounting surface. 3. and CAUTION: The choke coil. Inspect the upper and lower surfaces of the float bowl to see that the small sealing beads are not damaged. Inspect the steps on the fast idle cam for excessive wear. . Do not overtighten. 4. If removed. 5. If removed. If removed. and attaching screws. Do not pass drills through jets or passages. Clean and dry all passages in casting with compressed air. Clean pump in clean gasoline only. replace cam to assure proper engine operation during the warm-up and choking periods. 5. install compensator and gasket between the two large venturi. replace the pump plunger as an assembly. 8. 3. then install the attaching screw. The lever should extend upward between the attaching screw bosses. install the idle mixture needles and springs in the throttle body. 8. 6. Clean filter of dirt or lint. If filter is plugged. If removed. seat and gasket assembly. Check float for dents or excessive wear at hinge pin holes. Install the choke housing gasket. Install the pump discharge (steel) ball. using two self-tapping screws. install the slow idle speed screw. Install the intermediate choke lever and shaft. If grooved. install the choke piston on the link so that the piston hole is facing outward. 6. Install the main metering valve. install the fast idle lever on the end of the throttle shaft with attaching screw. Inspect the pump plunger for cracks or creases. the worn parts should be replaced. Inspect holes in pump rocker arm. then back out 1-1/2 turns as a preliminary idle adjustment. 7. Shake float to check for leaks. 9. Screw with gasket must be inserted in center hole. gasket. If equipped with idle compensator. If damaged. 9. it should be replaced. CARBURETOR ASSEMBLY THROTTLE BODY (Fig. Position the fast idle cam on the throttle body and install attaching screw. jets and power 5. 2. If holes are worn excessively or out-of-round to the extent of improper operation of the carburetor. 4. 1. Install the choke piston lever and link assembly in the choke housing.6M-20 Model 2GC Carburetion NOTE: No attempt should be made to r e move the throttle valves or shaft as it may be impossible to reassemble the throttle valve correctly in relation to the idle discharge orifices. Thoroughly clean carburetor castings metal parts in carburetor solvent. Install the pump inlet screen and the baffle in the float bowl. Examine float needle and seat.

install choke unloader lever on choke shaft. Then connect lower end of rod to fast idle lever. a. Install and tighten the eight air horn screws evenly and securely. 7. See adjustment specification chart. 5. Then connect lower end of rod to intermediate lever retaining with horseshoe clip. 3. Install seat in air horn with BT-52. 5. 6. 4. position the pump inner lever in the air horn. install the pump lever and shaft and tighten retaining screw. Bend the tang toward the seat to decrease the float drop and away from the seat to increase the drop. Install the air horn on the float bowl while .020" clearance should be maintained between choke unloader lever and the air horn casting. 2. Install the fuel iniet filter screen with the closed end inward.6 2 ) 1. Tighten choke valve screws and stake lightly in place. NOTE: Lubricate shaft with light grease. 6M-62 Carburetor Assembly guiding accelerator pump in place. FLOAT LEVEL ADJUSTMENT Fig. 2. Tang on unloader lever faces outward. Center the choke valve before tightening choke valve screws. Make adjustment as outlined in adjustment specification chart. Install choke unloader rod into unloader lever (end of rod facing inward). Install the choke valve screws. Install the choke shaft in air horn by inserting it from the choke side. See adjustment specification chart. 6 M . retaining with clip. Make sure piston travels freely. then install choke valve in the choke shaft with the letters RP facing upward. then install the inlet fitting and gasket. recheck the float level setting. Install intermediate choke rod into upper choke lever (end of rod facing inward). Position the upper end of the pump rod on the pump lever and retain with spring clip. Install the air horn gasket. Install the power piston and lightly stake the casting. Install the pump plunger shait in tne pump lever so that the end is pointing inward. . float and needle assembly and float hinge pin. then install the retainer. COMPLETION OF CARBURETOR ASSEMBLY (Fig. If it is necessary to bend the float arm for alignment purposes. Position idle vent valve and shield on air horn and retain with attaching screw. Position the float needle seat gasket and small filter screen on the seat.Model 2GC Carburetion 6M-21 AIR HORN i if removed. If removed. bend the float tang which contacts the needle seat. FLOAT DROP ADJUSTMENT If necessary to adjust. 3. 6. 4. Make sure the float is properly aligned on the air horn.

6M-22 Model 2GC Carburetion .

Model 4MV Carburetion 6M. 6M-75 Float System .23 MODEL 4 M V CARBURETOR Subject Page Subject Page GENERAL DESCRIPTION THEORY OF OPERATION FLOAT SYSTEM IDLE SYSTEM OFF IDLE OPERATION HOT IDLE COMPENSATOR MAIN METERING SYSTEM POWER SYSTEM AIR VALVE DASHPOT ACCELERATING PUMP SYSTEM CHOKE SYSTEM CARBURETOR REMOVE AND INSTALL 6M-23 6M-24 6M-24 6M-24 6M-26 6M-26 6M-26 6M-27 6M-29 . . 6M-30 6M-31 6M-32 CARBURETOR DISASSEMBLY 6M-32 AIR HORN REMOVAL 6M-33 AIR HORN DISASSEMBLY 6M-33 FLOAT BOWL DISASSEMBLY 6M-33 THROTTLE BODY DISASSEMBLY . 6M-39 ADJUSTMENTS 6M-40 ADJUSTMENT CHART 6M-41 equipped with plain tube nozzles. GENERAL DESCRIPTION The Quadrajet is a 4-barrel carburetor having two stages of operation. Its metering principles are similar to most plain tube carburetors using the venturi principle. . . 6M-36 CLEANING AND INSPECTION 6M-36 CARBURETOR ASSEMBLY 6M-37 THROTTLE BODY 6M-37 FLOAT BOWL 6M-37 AIR HORN 6M-38 AIR HORN TO BOWL INSTALLATION . The primary (fuel inlet) side has small bores with a triple venturi set-up Fig. . Fuel metering in the primary side is accomplished with tapered metering rods positioned by a manifold vacuum responsive piston.

They are float. The purpose of the internal vents is to balance incoming air pressure beneath the air cleaner with air pressure acting on fuel in the float bowl. The fuel enters the chamber above the float valve tip and due to pressure tends to force the float needle downward (closed). fastened to the float valve stem. hooks over the center of the float arm above the needle valve. A sintered bronze fuel inlet filter is mounted in the fuel inlet casting which is an integral part of the float bowl. This maintains a more constant fuel level during this type maneuver. The primary side of the carburetor has six systems of operation. and choke. Using the air valve principle. When the throttle valves are in the engine idle position. a balanced air/fuel mixture ratio can be maintained during part throttle and power operation because the same pressure acting upon the fuel in the float bowl will be balanced with the air flow through the carburetor bores. power. This prevents rough engine idle and excessively long hot engine starting.6M-24 Model 4MV Carburetion The secondary side has two very large bores which have greatly increased air capacity to meet engine demands. and opens the valve. constantly maintaining a positive fuel level in the float bowl. This block prevents fuel slosh on severe brake applications. float valve diaphragm retainer and screws. and retainer combination. It passes through the filter element and on into the float inlet valve chamber. main metering. The following text describes all systems of operation in detail for ease in servicing and troubleshooting. the fuel vapors are allowed to vent externally. plastic float pontoon assembly. During hot engine soak. 6M-76) The idle system is used only in the two primary bores of the carburetor. Therefore. Each bore has a separate . returning the carburetor to the internally balanced venting. It has the ability to remove dirt particles of 80 microns (. The fuel enters the float chamber at the top to prevent incoming fuel vapors from mixing with solid fuel in the bottom of the float bowl and disrupting good carburetor metering. A float needle pull clip. to prevent stalling. allowing fuel to pass by the open float valve and enter the fuel passage leading to the float chamber.003") in diameter. The air valve principle is used in the secondary side for metering control and supplements fuel flow from the primary bores. a float valve and diaphragm assembly. The fuel p r e s sure acting on the diaphragm raises the needle off its seat. and a float valve pull clip. an actuating link on the pump lever strikes the spring arm on the idle vent valve. 6M-75) The float system consists of a float chamber. The internal vent tubes allow the escape of fuel vapors in the float chamber during hot engine operation. The float system operates as follows: Fuel from the engine fuel pump enters the carburetor fuel inlet passage. The pressure on this diaphragm tends to force the float valve upward and pull the float valve off its seat. IDLE SYSTEM (Fig. which can result in fuel spillage into the carburetor bores. Thus. The same pressure in the float valve chamber also acts upon the small diaphragm fastened to the top of the float valve stem. pump. an external idle vent valve is used to vent fuel vapors to the outside. As incoming fuel fills the float bowl to the p r e scribed fuel level. the float pontoon rises and forces the fuel inlet valve closed. The carburetor float chamber is both internally and externally vented. Its purpose is to assist in lifting the float valve off its seat whenever fuel pump pressure or the fuel level in the float bowl is low. the idle vent valve closes. This prevents fuel vaporization from causing excessive pressure build-up in the float bowl.position. Internal vent tubes are located in the primary bore section of the carburetor air horn just above the float chamber. shutting off all fuel flow. idle. This fuel passage leads upward to a point just above normal liquid level and the fuel spills over into the float bowl. thereby preventing them from entering the carburetor bores and being drawn into the engine. located on the top of the primary side of the air horn. When the throttle valves are opened to the offidle and part throttle. THEORY FLOAT SYSTEM (Fig. A plastic filler block is located in the top of the float chamber in the area just above the float valve. The float needle valve is pressure balanced to permit use of a small float to control fuel "shut-off" through the large fuel inlet needle seat. fuel is metered in direct proportion to the air passing through the secondary bores. As fuel is used from the float chamber the float drops and allows more incoming fuel to enter the float bowl until the correct fuel level is reached. The fuel reservoir is centrally located and uses a single float pontoon. The secondary side has one metering system which supplements the primary main metering system and receives fuel from a common float chamber. This cycle continues. float hinge pin.

The small amount of air which passes between the primary throttle valve and bore is regulated by this screw to give the engine the desired idle speed. The fuel is mixed with air at the top of each idle tube through an idle air bleed. Turning the mixture screw clockwise (inward) decreases the fuel discharge (gives a leaner mixture) and turning the mixture . It then passes down the idle channel past the lower idle air bleed holes and off-idle discharge ports. It passes from the main fuel well into the idle passage where it is picked up by the idle tubes. The fuel is metered at the tip of the idle tubes and passes up through the idle tubes. the idle system operates as follows: Fuel is forced from the float bowl down through the primary metering jets into the main fuel well. During curb idle the throttle valve is held slightly open by the idle speed adjusting screw. where it enters the carburetor bores and mixes finally with air passing around the slightly open throttle valve. The air/fuel mixture then moves down to the idle needle discharge holes. The idle mixture needles are adjustable and control the amount of fuel mixed with the air going to the engine. Since the engine requires very little air for idle and low speeds. It then enters the intake manifold and is conducted to the engine cylinders as a combustible mixture.Model 4MV Carburetion 6M-25 Fig. They consist of idle tubes. and idle discharge holes. just above the primary throttle valves where it is mixed with more air. fuel is added to the air to produce a combustible mixture by the direct application of vacuum (low pressure) from the engine manifold to the idle discharge hole below the throttle valve. idle mixture adjustment needles. idle channel restrictions. idle air bleeds. With the idle discharge holes in a very low pressure area and the fuel in the float bowl vented to atmosphere (high pressure). idle passages. 6M-76 Idle System and independent idle system. The fuel mixture then crosses over to the idle down channels where it passes through a calibrated idle channel restriction.

a finger may be held over the compensator air inlet channel located on top of the air horn. fuel flows from the main discharge nozzles as follows: Fuel flows from the float bowl through the main metering jets into the main fuel well and is bled . the bimetal strip bends and unseats the compensator valve. Since the low pressure (vacuum) is now in the smallest boost venturi. additional fuel is needed to combine with the extra air entering the engine. This is accomplished by the slotted off-idle discharge ports. air velocity increases in the carburetor venturi. Manifold vacuum holds the main metering rods down in the main metering jets against spring tension. The compensator consists of a thermostatically controlled valve. To check this. when extra air is needed to offset the enrichening effects of fuel vapors. As the primary throttle valves are opened beyond the off-idle range allowing more air to enter the engine manifold. When the engine cools and the extra air is not needed. The compensator valve assembly is held in place by the dust cover over the valve chamber. The system operates as follows: During cruising speeds and light engine loads. The idle needle holes and off-idle discharge ports continue to supply sufficient fuel for engine requirements until air velocity is high enough in the venturi area to obtain efficient fuel flow from the main metering system. As the primary throttle valves open. Otherwise the compensator will not function if the plug is left in the hole. As a result. The air bleed leads from the top of this channel into the top of the main fuel well where it is vented into the air horn above the venturi. If the valve is open. Further opening of the throttle valves increases the air velocity through the carburetor venturi sufficiently to cause low pressure at the lower idle air bleeds. In order to insure proper idle adjustment when the engine is hot. engine manifold vacuum is high. This allows enough air to be drawn into the engine manifold to offset the richer mixtures and maintain a smooth engine idle. they pass by the off-idle ports. main well air bleeds. The purpose of the bleed is to allow any fuel vapors in the idle tube channel during hot idle to escape and prevent them from mixing with fuel being picked up by the idle tube. It should be noted there is an idle air bleed located in each idle tube. This uncovers the air channel leading from the valve chamber to the point below the throttle valves. If no drop in engine rpm is noted on the tachometer. Normally the compensator valve is held closed by tension of the bi-metal strip. and triple venturi. a bi-metal strip which is heat sensitive. just beneath the air cleaner. the bi-metal strip closes the valve and operation returns to normal mixtures. excessive fuel vapors en- tering the engine manifold cause richer than normally required mixtures. MAIN METERING SYSTEM (Fig.venturi which is increased many times in the double boost venturi. This gives a more consistent idle fuel mixture during periods of hot engine idling. At a predetermined temperature. to a point below the secondary throttle valves. The valve closes off an air channel which leads from a hole in the top of the air horn. Fuel flow from the float bowl is metered between the metering rods and main metering jet orifice. main fuel well. the compensator valve must be closed. This causes a drop in pressure in the large. A seal is used between the compensator valve and the float bowl casting. supplementing the main discharge nozzle delivery. a valve holder and bracket. fuel begins to discharge from the lower idle air bleed holes and continues to do so throughout operation of the part throttle to wide open throttle ranges. the valve is closed. HOT IDLE COMPENSATOR The hot idle compensator is located in a chamber at the r e a r of the carburetor float bowl adjacent to the secondary bores. The additional fuel added from the off-idle ports mixes with the increasing air flow past the opening throttle valves to meet increased engine air and fuel demands. During extreme hot engine operation. OFF IDLE OPERATION As the primary throttle valves are opened from curb idle to increase engine speed. Its purpose is to offset enrichening effects caused by excessive fuel vapors during hot engine operation. NOTE: Plug the compensator hole with something that will be seen. 6M-77) The main metering system consists of main metering jets. Manifold vacuum is supplied through a channel to the vacuum operated power piston connected to the primary main metering rods. gradually exposing them to high engine vacuum below the throttle valves. fuel discharge nozzles. resulting in rough engine idle and stalling.6M-26 Model 4MV Carburetion screw counterclockwise (outward) increases (enrichens) the idle fuel mixture. vacuum operated metering rods. plug the hole or cool engine down to a point where the valve is closed for proper idle adjustment. as the plug must be removed before the air cleaner is installed.

At the boost venturi the fuel mixture then combines with the air entering the engine through the carburetor bores and passes through the intake manifold and on into the engine cylinder as a combustible mixture. When manifold vacuum rises and mixture enrichment is no longer needed. as engine load is increased to a point where extra mixture enrichment is required. secondary metering rods. 6M-77 Main Metering System with air from the vent at the top of the main well and side bleeds (one which leads from inside the bore area above the venturi and another from the cavity around the main fuel nozzle into the main well). The richer mixture is supplied through the main metering system in the primary and secondary sides of the carburetor. manifold . metering orifice discs. and accelerating wells and tubes. the primary side of the carburetor can no longer meet the engine air and fuel requirements. The spring located beneath the vacuum operated power piston tends to push the piston upward against manifold vacuum. The secondary section contains throttle valves. The power system located in the primary side consists of a vacuum piston and spring located in a cylinder connected by a passage to intake manifold vacuum. however. as the engine speed increases. To meet these demands. spring loaded air valves. the vacuum overcomes the power piston spring tension and returns the larger portion of the metering rod into the metering jet orifice and back to normal economy ranges. fuel discharge nozzles. POWER SYSTEM (Fig. However. The fuel in the main well is mixed with air from the main well air bleeds and then passes through the main discharge nozzle into the boost venturi. Mixture enrichment is not necessary at this point.7 8 ) vacuums are sufficient to hold the power piston down against spring tension so that the larger diameter of the metering rod tip is held in the main metering jet orifice. the spring tension overcomes the vacuum pull on the power piston and the tapered primary metering rod tip moves upward in the main metering jet orifice. The smaller diameter of the metering rod tip allows more fuel to pass through the main metering jet and enrich the mixture flowing into the primary main wells and out the main discharge nozzles. 6 M . The secondary side operates as follows: The power system in the Quadrajet carburetor provides extra mixture enrichment for power requirements under heavy acceleration or high speed operation. the secondary side of the carburetor is used. main fuel wells with air bleed tubes. On part throttle and cruising ranges.Model 4MV Carburetion 6M-27 Fig.

They. Here fuel mixture is mixed with air traveling through the secondary bores to supplement the air/fuel mixture delivered from the primary bores. The cam pushes the lever upward. the upper edge of the air valve passes the accelerating well port. increased air flow through the secondary side of the carburetor opens the air valve to a greater degree which in turn lifts the secondary metering rods further out of the orifice discs. As the throttle valves are opened further.6M-28 Model 4MV Carburetion Fig. begin to feed fuel as follows: When the air valve begins to open it rotates a plastic cam attached to the center of the main air valve shaft. and engine speeds increase. When the air valve begins to open.7 8 Power System When the engine reaches a point where the p r i mary bores cannot meet engine air and fuel demands. The secondary main discharge nozzles (one for each secondary bore) are located just below the air valve and above the secondary throttle valves. As air flow through the secondary bores creates a low pressure (vacuum) beneath the air valve. and then goes on into the engine manifold and on to the engine cylinders as a combustible mixture. 6 M . The accelerating ports will prevent a momentary leanness as the valve opens and the secondary nozzles begin to feed fuel. begins to open the secondary throttle valves. The metering rods are tapered so that fuel flow through the secondary metering orifice discs is directly proportional to air flow through the secondary carburetor bores. raising the metering rods out of the secondary orifice discs. The port will immediately start to feed fuel from the accelerating wells. The air emulsified fuel mixture travels from the main wells to the secondary discharge nozzles and into the secondary bores. the primary throttle lever through connecting linkage to the secondary throttle shaft lever. atmospheric pressure on top of the air valve forces the air valve open against spring tension. In this manner correct air/fuel mixtures to the engine through the secondary bores can be maintained by the depth of the metering rods in the orifice discs. being in the area of lowest pressure. Fuel flows from the float chamber through the secondary orifice discs into secondary main wells. . The accelerating ports will continue to feed fuel until the fuel in the accelerating wells is depleted. As the valve passes the port it exposes the port to manifold vacuum. where it is mixed with air from the main well tubes. This allows the required air for increased engine speed to flow past the air valve. The cam pushes on a lever attached to the secondary main metering rods.

6 M . one in each secondary bore.7 9 ) The secondary air valve has an attached piston assembly which acts as a dampener. This closes off the area through the center of the piston and slows down the air valve opening to prevent secondary discharge nozzle lag. During hot engine idle or hot soak the fuel could boil away out of the fuel well. The motion of the piston is retarded by fuel which must bypass the piston when it moves up in the fuel well. to prevent oscillation of the valve due to engine pulsations. The dampener piston operates in a well which is filled with fuel from the float bowl. The milled slot allows enough fuel to bypass the orifice disc to keep the main well filled during this period. The purpose of the valve is to seat on the piston when the air valve opens and the piston rod moves upward. Two baffle plates are used. 1.Model 4MV Carburetion 6M-29 Fig. The secondary metering rods have a slot milled in the side to insure adequate fuel supply in the secondary fuel wells. The piston is attached loosely to a plunger rod. No further adjustment should be required. These actually bleed air into the fuel in the well to quickly emulsify the fuel with air for good atomization as it leaves the secondary discharge nozzles. The rod has a rubber seal which retains the dampener piston to the plunger rod and also acts as a valve. 2. the secondary metering rods are nearly seated against the secondary metering orifice discs. The main well bleed tubes extend below the fuel level in the main well. There are three other features incorporated in the secondary metering system which are as follows: . This insures immediate fuel delivery from the secondary fuel wells at all times. Their purpose is to provide good fuel distribution at lower air flows by preventing too much fuel from going to the front of the engine. These are necessary because when the air valve is in the closed position. 6M-79 Air Valve Dashpot The depth of the main metering rods in the orifice discs in relation to the air valve position are factory adjusted to meet the air/fuel requirements for the specific engine model. They extend up and around the secondary fuel discharge nozzles. 3. AIR VALVE DASHPOT (Pig.

6M-30 Model 4MV Carburetion Fig. operating in a fuel well. The fuel. The pump cup seats instantly and fuel is forced through the pump discharge passage. The top pump duration with the bottom pump return smooth sustained charge of during acceleration. tends to lag behind causing a momentary leanness. a momentary acceleration lag could result. The accelerating pump system is located in the primary side of the carburetor. When the primary throttle valves are opened the connecting linkage forces the pump plunger downward. When the pump plunger is moved upward the flat on the top of the cup unseats from the flat on the plunger head and allows free movement of fuel through the inside of the cup into the bottom of the pump well. The accelerator pump is used to provide the extra fuel necessary for smooth operation during this time. This also vents any vapors which may be in the bottom of the pump well so that a solid charge of fuel can be maintained in the fuel well beneath the plunger head. (The cup moves up and down on the pump plunger head). plunger is spring spring is balanced spring so that a fuel is delivered The pump discharge check ball seats in the pump discharge passage during upward motion of the pump plunger so that air will not be drawn into the passage. which is heavier. 6M-80 Accelerating Pump System ACCELERATING PUMP SYSTEM (Fig. The pump plunger is of a floating type. the air flow and manifold vacuum change almost instantaneously.8 0 ) During quick acceleration. When the pump plunger moves upward in the pump well. where it unseats the pump discharge check ball and passes on through the passage to the pump jets located in the air horn where it sprays into the venturi area of each primary bore. It flows past the synthetic pump cup seal into the bottom of the pump well. 6 M . It consists of a spring loaded pump plunger and pump return spring. It should be noted the pump loaded. The pump plunger is operated by a pump lever on the air horn which is connected directly to the throttle lever by a pump rod. . otherwise. as happens during throttle closing. fuel from the float bowl enters the pump well through a slot in the top of the pump well. when the throttle is opened rapidly.

the fast idle cam follower lever on the end of the primary throttle shaft will drop from the . The thermostatic coil located in the engine manifold is calibrated to hold the choke valve closed when the engine is cold. This insures a full pump stream when needed and prevents any fuel "pull over" from the pump discharge passage. This restricts air flow through the carburetor to provide the richer starting mixture required. NOTE: To close the choke valve the primary throttle valves have to be partially opened to allow the fast idle cam follower to bypass the steps on the fast idle cam and come to rest on the highest step of the fast idle cam. Choke operation is controlled by the combination of intake manifold vacuum. The thermostatic coil is located in the engine manifold and is connected to the intermediate choke shaft and lever assembly. a vacuum exists at the pump jets.Model 4MV Carburetion 6M-31 Fig. At the same time. 6 M . a vacuum diaphragm unit. air pressure against the top side of the choke valve causes the valve to open slightly against tension of the thermostatic coil. split choke pick up spring. A cavity just beyond the pump jets is vented to the top of the air horn. outside the carburetor bores. It provides the correct air/fuel mixture enrichment to the engine for quick cold engine starting and during the warm-up period. connecting linkage. 6M-81) The Quadrajet choke valve is located on the primary side of the carburetor. the air valve lockout lever is weighted so that a tang on the lever catches the upper edge of the air valve and keeps the air valve closed. During engine cranking. It results in more vacuum break at higher temperature (75° F+) and less vacuum break at cooler temperature. vacuum break modulating spring. CHOKE SYSTEM (Fig. and throttle position. fast idle cam. air valve lockout lever. the offset choke valve. The choke system consists of a choke valve located in the primary air horn bore.8 1 Choke System During high speed operation. temperature. When the choke valve is closed. and a thermostatic coil. This acts as a suction breaker so that when the pump is not in operation fuel will not be pulled out of the pump jets into the venturi area. The vacuum break modulating spring allows the vacuum break (choke valve position) to vary according to ambient temperature. When the engine starts and is running manifold vacuum applied to the vacuum diaphragm unit mounted on the float bowl will open the choke valve to a point where the engine will run without loading or stalling. The air valve is locked closed until the engine is thoroughly warm and choke valve is wide open.

The Quadrajet carburetor split choke feature operates during the l a s t . Remove the two rear carburetor to manifold attaching nuts.95 can be used to disconnect the line. it is essential that the carburetor be placed on a holding fixture. 5. A tang on a lever on the choke side of the primary throttle shaft contacts the fast idle cam and through the intermediate choke shaft forces the choke valve slightly open. the choke coil pulls the intermediate choke lever completely down and allows the fast idle cam to rotate so that the cam follower drops off the last step of the fast idle cam allowing the engine to run at 1. As the rod moves to the end of its travel. reverse the removal procedure using a new carburetor to manifold gasket.6M-32 Model 4MV Carburetion normal idle speeds. The split choke torsion spring has adjustment notches and should always be placed in the specified notch for the application used. it pushes the lockout tang upward and unlocks the air valve. 6. 6M. As the thermostatic coil on the engine manifold becomes heated. 4 M V CARBURETOR DISASSEMBLY NOTE: Before performing any service on this carburetor. In the last few degrees of thermostatic coil opening. lbs. When the choke valve moves toward the open position. Disconnect vacuum hoses. 3. Disconnect carburetor rod. . Refer to ENGINE Section for idle specifications. This keeps the fast idle cam follower lever on the last step of the fast idle cam to maintain fast idle until the engine is thoroughly warm. When the engine is thoroughly warm. should the engine become loaded or flooded during the starting period. air pressure action on the off-set choke valve tends to force the choke valve open against tension of the thermostatic coil. To unload the engine the accelerator pedal should be depressed so that the throttle valves are wide open. Remove air cleaner. NOTE: A tool such as MAC S-141 as shown in Fig. This gives the engine sufficient fast idle and correct fuel mixture for running until the engine begins to warm up and heat the thermostatic coil. Choke valve opening continues until the thermostatic coil is completely relaxed at which point the choke valve is wide open. lbs. Torque the attaching bolts (6-8 ft. Disconnect fuel inlet line. The choke system is equipped with an unloader mechanism which is designed to partially open the choke valve. The purpose is to maintain fast idle speed long enough to keep the engine from stalling but allow the use of a choke coil which lets the choke valve open quickly. 6M-82 4MV Carburetor Assembly REMOVE A N D INSTALL highest step on the fast idle cam to the second step if the throttle is opened. Remove air cleaner stud. until the coil is hot enough to pull on the intermediate choke lever and overcome the torsion spring tension. 4 M V CARBURETOR ASSEMBLY Fig. The secondary throttle valves in the wide open position extend below the throttle body casting. 4. the end of the choke rod strikes a tang on the air valve lockout lever. it relaxes its tension and allows the choke valve to open further because of intake air pushing on the off-set choke valve. Without the use of the carburetor stand it is possible to bend or nick the aluminum throttle valves. This allows extra air to enter and lean out the fuel mixture so that the engine will start. Remove the two front carburetor to manifold attaching bolts (slotted). few degrees of choke thermostat rotation. 2. 7.) and nuts to 14 ft. It actually works against the thermostatic coil. As explained earlier. a tang on the intermediate choke lever contacts the end of the torsion spring. The operation of the split choke is controlled by a torsion spring on the intermediate choke lever shaft. To install.

air valve shaft and secondary metering rod hanger are calibrated and should not be removed. FLOAT BOWL DISASSEMBLY 1. (Fig. Remove pump return spring and plastic filler. 6M-83) (Fig. Gasket should r e main on bowl. remove dashpot from air horn by rotating bend through air horn. the choke valve. 6M-87) 5. If part r e placement is required. Remove power piston and primary metering rods by pulling straight up on metering rod hanger directly over power piston and remove power piston spring from well (Fig. Disconnect pump rod from pump lever. With carburetor on holding fixture. Lift air horn straight up. 6M-86) 2. 6M-84 Air Horn Removed AIR HORN REMOVAL 1. (Fig. (Fig. remove idle vent valve. Remove air horn attaching screws. 6M-84) rods from 2. 6M-84) Further disassembly of the air horn is not required for cleaning purposes. Tubes are pressed in casting and are not to be removed. 6M-85) NOTE: Air valves. (Fig. Remove dashpot from air valve link by rotating bend through hole. 6M. 6M-87). Remove secondary metering hanger. 6M-83 Air H orn Attaching Screws Fig.Model 4MV Carburetion 6M-33 Fig. (Fig. AIR HORN DISASSEMBLY 1. 3. Remove clip from upper end of choke rod and remove choke rod. 6M-82) 4. Fig. Remove pump and air horn gasket from around power piston and primary metering rods. (Fig. 6M-82) 3. pump lever and air valve lever can be removed. then. (Fig. (Fig. 6M-85 Air Horn Assembly . (Fig. 6M-82) 2.84) NOTE: Do not bend main well air bleed tubes.

6M-89) 10. 7. (Fig. being careful not to destroy pull clip. 6 M . remove clip and spring from vacuum break link. Remove vacuum hose from vacuum break assembly and from tube connection on bowl. at vacuum break lever. 6M-89) 6. 6 M . Remove float retaining pin and slide float a s sembly toward front of bowl to disengage needle pull clip. (Fig. 6M-89) NOTE: Needle seat is factory staked.8 9 Float Assembly 8. 6 M . Do not attempt to remove or restake. If damaged. 6 M . Remove pump discharge check ball retainer and check ball.6M-34 Model 4MV Carburetion Fig. (Fig. then . 6M-90) Fig. Remove primary metering jets. (Fig. Remove metering rods from power piston bydisconnecting tension spring from top of each rod then rotating rod to remove from hanger. replace float bowl assembly. (Fig. (Fig. Remove float retainer and needle assembly. (Fig. Remove baffles from secondary side of bowl. 6M-90) 9.8 6 Pump Assembly Fig. Remove choke assembly. No attempt should be made to remove secondary metering discs. 6M-91) 11.8 8 M e t e r i n g Rods and Power Piston Assembly Fig. (Fig. 6M-91) NOTE: If further disassembly of choke is necessary. 6M-88) 5.8 7 Power Piston Assembly 4.

Fig. Remove hot idle compensator from float bowl. (Fig. 6M-94 Hot Idle Compensator remove rod from vacuum break lever. If necessary to replace the choke actuating lever or spring it will be necessary to remove the roll pin. (Fig. Remove fast idle cam from choke assembly.35 Fig. then remove vacuum break assembly from lever. Spread the retaining ears on bracket next to vacuum break assembly. (Fig. (Fig. 6M-93) NOTE: Do not place vacuum break assembly in carburetor cleaner. 6M-93 Fast Idle Cam Fig. 13. 6M-93) 12. 6M-94) and O-ring . 6M-91 Choke Assembly Fig. 6M-92 Vacuum Break Assembly 14. 6M-90 Primary Metering Jets Fig.Model 4MV Carburetion 6M. 6M-92). Remove lower choke rod and actuating lever from inside of float bowl well.

Remove throttle body and throttle body to bowl gasket. 6M-96) THROTTLE BODY DISASSEMBLY 1. 6M-95) filter 1. (Fig. Do not pass drills through jets or passages. and spring. 6M-96 Throttle Body Attaching Screws 15. pump plungers should not be immersed in carburetor cleaner. (Fig. 6M-97) NOTE: No further disassembly throttle body is required. plastic parts. Inspect idle mixture needles for damage. idle mixture screws and springs. the delrin cam on the air valve shaft will withstand normal cleaning in carburetor cleaner.6M-36 Model 4MV Carburetion Fig. (Fig. Thoroughly clean carburetor castings and metal parts in an approved carburetor cleaner such as Carbon X (X-55) or its equivalent. 3. 6M-95 Fuel Filter Nut Fig. 6M-97 Throttle Body Fig. 6M-98 Throttle Body Gasket CLEANING AND INSPECTION NOTE: The carburetor should be cleaned in a cold immersion type cleaner. However. 16. 2„ Blow out all passages in castings with compressed air. Fig. of the . Remove fuel inlet filter nut. gasket. diaphragms. Remove pump rod. NOTE: Any rubber parts.

then. 6M-96) Place carburetor on proper holding fixture. install hot idle compensator. 6. (Fig. Inspect upper and lower surfaces of carburetor castings for damage. (Fig. air horn assembly must be replaced. filter. If worn. 6M-99 Hot Idle Compensator " O " Ring 1. levers should be replaced. 6M-99) NOTE: If vacuum break diaphragm was removed from bracket. 6M-101 Installing Fast Idle Car . 6M-98) 2. new gasket and inlet nut and tighten nut securely. Install idle mixture needles and springs until seated. FLOAT BOWL 1. 6M-100 Vacuum Break Diaphragm Fig. 4 M V CARBURETOR ASSEMBLY THROTTLE BODY Fig. Inspect holes in levers for excessive wear or out-of-round conditions. Check air valve for binding conditions. 5. Install throttle body making certain throttle body is properly located over dowels on float bowl. Check all throttle levers and valves for binds or other damage. Install fuel inlet filter spring. 2. 3. 6M-97) Back out needles two turns as a preliminary idle adjustment. 6M-100) 5. then. Install fast idle cam on vacuum break assembly. Install new throttle body to bowl gasket over two locating dowels on bowl. (Fig. 7. 8. slide vacuum break diaphragm between retaining ears to hold securely. Examine float needle and diaphragm for wear. Examine fast idle cam for wear or damage. Install vacuum break rod (U-bend end) in diaphragm link with end towards bracket. Be sure fast idle cam actuating pin on Fig. Replace if necessary with new float needle assembly. Install spring.Model 4MV Carburetion 6M-37 4. Install pump rod in throttle lever by rotating rod. If air valve is damaged. (Fig. 9. 6M-95) 4. (Fig. install throttle body to bowl screws and tighten evenly and securely. Install hot idle compensator " O " ring seal in recess in bowl. (Fig. then. install grooved end of rod in hole of actuating lever and retain to vacuum break lever with spring clip.

18. (Fig. Fig. 6M-101) 6. 6M-103 Float Needle and Diaphragm Assembly gauging point 3/16" back from toe). then holding choke rod. making sure that tension spring is connected to top of each metering rod. 6M-102) (Fig. 12. if removed. measure from top of float bowl gasket surface (gasket removed) to top of float at toe (locate 14. 6M-103) Install needle retainer and two screws and tighten securely. 7. up or down for proper 10. 6M-105) 16. . p r e s s ing downward until seated properly. Install the following. With float lever in pull clip. 15. With adjustable T-scale. Be certain diaphragm is properly positioned before installing retainer. 11. Install float by sliding float lever under pull clip from front to back. Bend f l o a t adjustment. Install vacuum hose to tube connection on bowl and vacuum break assembly. Install air horn gasket around primary metering rods and piston. Install pump lever and retain with roll pin. 13. Install pump discharge check ball and retainer in passage next to pump well. Install power piston spring in power piston well.6M-38 Model 4MV Carburetion Fig. (Fig. position choke rod actuating lever in well of float bowl and install choke assembly engaging shaft with hole in actuating lever. 6M-102 Installing Primary Metering Jet intermediate choke shaft is located in cut out area of fast idle cam. P r e s s down firmly on power piston to insure engagement. 17. If primary main metering rods were removed from hanger. Be careful not to distort pull clip. (Fig. Remove choke rod from lever for installation later. Using needle nosed pliers to hold needle pull clip. 9. NOTE: Make sure retaining pin is held firmly in place and tang of float is seated on float needle. Position gasket over two dowels on secondary side of bowl. install pull clip on needle. Install retaining screw and tighten securely. with grooved end pointing inward. a. Install pump plunger in pump well. Refer to ADJUSTMENT Chart for specifications. Insert float needle and diaphragm assembly. Float Level Adjustment a. 8. b. hold float assembly at toe and install retaining pin from pump well side. Install primary main metering jets. Install plastic filler over float needle. Connect choke rod to choke rod actuating lever (plain end). reinstall. Pull clip is properly positioned with open end towards front of bowl. 6M-104) Install power piston assembly in well with metering rods properly positioned in metering jets. Install pump return spring in pump well. AIR HORN 1. (Fig.

(Fig. 2. 6M-105 Installing Plastic Filler Secondary Metering Rods b. 6M-107) 3. (Fig. Install secondary metering rods. 6M-104 Power Piston Assembly j «. vent tubes and accelerating well tubes through air horn gasket. Do not force air horn assembly on to float bowl as distortion of secondary metering discs will result.Model 4MV Carburetion 6M-39 Fig. 1. Install choke shaft. 6M-106 Fig. rods should be positioned with upper ends through hanger holes and towards each other. Install dashpot plunger rod through air horn and attach actuating lever to rod. c. 6M-105A Metering Rod Installation Fig. 6M-105A) AIR H O R N TO B O W L INSTALLATION positioning secondary metering rods. Install air horn screws. A slight sideward movement will center metering rods in metering discs. 6M-106) 2. With air valve held wide open. tighten evenly and securely. choke valve and two attaching screws. (Fig. ^ P j Fig. . Care should be taken when installing to be sure dashpot and pump plunger are positioned properly through air horn. Place air horn assembly on bowl carefully. Install idle vent actuating rod in pump lever.

at torsion spring end. 6 M . 5. When the choke valve is moved towards closed position to remove looseness in the linkage. at choke lever end. Refer to ADJUSTMENT Chart. open the choke valve to its wide open stop position. rotate the choke valve toward the closed position by pushing down on the vacuum break lever. With the valves in this position. . Refer to ADJUSTMENT Chart. Position pump rod in inner hole pump lever and retain with spring clip. to top of pump stem. next to vent stack. Idle Vent Adjustment With the choke valve held in the closed position. apply a light force to the vacuum break lever in the direction of closed choke. Bend the tang on the fast idle lever to adjust. next to vent stack. Dimension between the lower edge of choke valve. the distance between upper inside edge of air valve and the back of choke valve wall.6M-40 Model 4MV Carburetion Fast Idle Adjustment With primary throttle valves completely closed and the cam follower over the high step of the fast idle cam. Bend choke rod to adjust. should be as specified on ADJUSTMENT Chart. measure from top of choke valve wall. should be as specified on ADJUSTMENT Chart.015" to . open the primary throttle to the wide open position. Bend vacuum link to adjust.035" between the lockout lever and the front edge of the air valve. Bend stop tang on dashpot lever to adjust. 4 M V CARBURETOR EXTERNAL ADJUSTMENTS (Fig. 6. Air V a l v e Adjustment With the cam follower on the high step of the fast idle cam. Vacuum Break Adjustment Fig. turn fast idle screw in three turns after screw makes contact on lever. With the cam follower positioned against the r i s e to the lowest effective step of the fast idle cam. Unloader Adjustment With throttle valves completely closed and pump rod in specified hole of pump lever. the dimension between the lower edge of choke valve and air horn wall should be as specified on ADJUSTMENT Chart. Refer to ADJUSTMENT Chart.300" clearance between the tang and the front leg of the choke tension spring. Adjust the inner arm of the spring tang on the vacuum break bracket so there is . 6M-107 Installing Air Horn 4. engaging actuating rod and tighten attaching screw. Bend pump lever to adjust. Choke Rod Adjustment With the fast idle adjustment made and cam follower on second step of fast idle cam and against the high step. should be as specified on ADJUSTMENT Chart. hold the choke valve toward the closed position using a rubber band on the vacuum break lever. the air valve should be unlocked with a clearance of . Install idle vent valve. With the vacuum break lever in this position and the choke valve is moved towards open choke to remove looseness in the linkage. to top of the pump plunger stem. Refer to ADJUSTMENT Chart. the air valve must be locked. Connect choke rod in lower choke lever and retain in upper lever with spring clip. by a rubber band on the vacuum break lever. Bend wire tang on pump lever to adjust. Hold vacuum break diaphragm stem against its seat so vacuum link is at the end of slot. open primary throttle to a point where the idle vent just closes. Split Choke Spring Pick-Up After pump rod adjustment has been made. The dimension between the lower edge of choke valve and air horn.1 0 9 ) Pump Rod Adjustment With choke spring pickup located in top notch. at choke lever end. Air V a l v e Lock With air valve wide open and valve against stop tang. Measure the distance from the top of choke valve wall.

Model 4MV Carburetion 6M-41 Fig. 6M-103 2GC Carburetor Adjustments .

POS. SPR'..300" . V-8" 70262507036250 70262547036254 11/32" 9/32" 3/8" 1-1/8" . LOCKOUT CHOKE UPPER NOTCH (R) FAST IDLE SEE "ON CAR ADJ. VACUUM BREAK UNLOADER AIR VALVE AUTOMATIC ADJMT. UPPER NOTCH SPLIT CH. 6M-109 4 M V C a r b u r e t o r Adjustments . ADJ.120" .300" .015 . SPR.6M-42 Model 4MV Carburetion USAGE FLOAT LEVEL PUMP ROD IDLE VENT AIR VALVE CHOKE ROD SPLIT CH.035 Fig.170" .

T. and M. Tags on K-19 equipped c a r s are square and all others are triangular shaped. in. in.T. with A/C M.T. and M.T. A. A.T. in. L-6 with K-19 A. A. Blue Orange Purple Plain Yellow Orange White *Part Number stamped on tag.T.T.T. .T. PART NO.T.F Model 4MV Carburetion 6M-43 CARBURETOR USAGE CHART *CARB.T. L-6 A. and M. .T. A. with K-19 4 2 5 cu.T. .T.T.T. in. and M.T. Model 4MV carburetors use a tag with a square hole if equipped with K-19.T. A. A.T. and M. and M. with K-19 Gold Gold Dk.T.T.T.T.Automatic Transmission M. A. and M.T. 2 5 0 cu. **A.T. with A/C and K-19 4 2 5 cu. Blue Gold Silver Gold Silver Orange Purple Lt. with A/C A.T. A. in. A. M. Model YF 408OS-3880860 Model BV 7026028 7026027 2GC 7026058 7026059 7036058 7036159 7026052 7026053 7026054 7036052 7036053 4MV 7026254 7036254 7026250 7036250 TAG COLOR ** USAGE 2 5 0 cu. with A/C and K-19 3 3 0 cu. with K-19 A. in. 3 3 0 cu.T.T.Manual Transmission . and M. and M. and M. with K-19 A.

6M-44 Model 4MV Carburetion .